Method of applying buttresses to surgically cut and stapled sites

ABSTRACT

A method of applying a buttress to a surgically cut and stapled site uses an end effector with a buttress applier cartridge assembly to load one or more buttress assemblies to the end effector. The buttress assemblies each include a buttress to support a staple formed therein as well an adhesive for adhering to the end effector. The adhesive of the buttress assemblies can include a pattern to assist in both attachment to the end effector and release from the end effector after cutting and stapling a tissue site. The buttress applier cartridge can include features that accommodate end effectors having various tip configurations, including straight tips and curved or bent tips.

BACKGROUND

In some settings, endoscopic surgical instruments may be preferred overtraditional open surgical devices since a smaller incision may reducethe post-operative recovery time and complications. Consequently, someendoscopic surgical instruments may be suitable for placement of adistal end effector at a desired surgical site through the cannula of atrocar. These distal end effectors may engage tissue in a number of waysto achieve a diagnostic or therapeutic effect (e.g., endocutter,grasper, cutter, stapler, clip applier, access device, drug/gene therapydelivery device, and energy delivery device using ultrasonic vibration,RF, laser, etc.). Endoscopic surgical instruments may include a shaftbetween the end effector and a handle portion, which is manipulated bythe clinician. Such a shaft may enable insertion to a desired depth androtation about the longitudinal axis of the shaft, thereby facilitatingpositioning of the end effector within the patient. Positioning of anend effector may be further facilitated through inclusion of one or morearticulation joints or features, enabling the end effector to beselectively articulated or otherwise deflected relative to thelongitudinal axis of the shaft.

Examples of endoscopic surgical instruments include surgical staplers.Some such staplers are operable to clamp down on layers of tissue, cutthrough the clamped layers of tissue, and drive staples through thelayers of tissue to substantially seal the severed layers of tissuetogether near the severed ends of the tissue layers. Merely exemplarysurgical staplers are disclosed in U.S. Pat. No. 4,805,823, entitled“Pocket Configuration for Internal Organ Staplers,” issued Feb. 21,1989; U.S. Pat. No. 5,415,334, entitled “Surgical Stapler and StapleCartridge,” issued May 16, 1995; U.S. Pat. No. 5,465,895, entitled“Surgical Stapler Instrument,” issued Nov. 14, 1995; U.S. Pat. No.5,597,107, entitled “Surgical Stapler Instrument,” issued Jan. 28, 1997;U.S. Pat. No. 5,632,432, entitled “Surgical Instrument,” issued May 27,1997; U.S. Pat. No. 5,673,840, entitled “Surgical Instrument,” issuedOct. 7, 1997; U.S. Pat. No. 5,704,534, entitled “Articulation Assemblyfor Surgical Instruments,” issued Jan. 6, 1998; U.S. Pat. No. 5,814,055,entitled “Surgical Clamping Mechanism,” issued Sep. 29, 1998; U.S. Pat.No. 6,978,921, entitled “Surgical Stapling Instrument Incorporating anE-Beam Firing Mechanism,” issued Dec. 27, 2005; U.S. Pat. No. 7,000,818,entitled “Surgical Stapling Instrument Having Separate Distinct Closingand Firing Systems,” issued Feb. 21, 2006; U.S. Pat. No. 7,143,923,entitled “Surgical Stapling Instrument Having a Firing Lockout for anUnclosed Anvil,” issued Dec. 5, 2006; U.S. Pat. No. 7,303,108, entitled“Surgical Stapling Instrument Incorporating a Multi-Stroke FiringMechanism with a Flexible Rack,” issued Dec. 4, 2007; U.S. Pat. No.7,367,485, entitled “Surgical Stapling Instrument Incorporating aMultistroke Firing Mechanism Having a Rotary Transmission,” issued May6, 2008; U.S. Pat. No. 7,380,695, entitled “Surgical Stapling InstrumentHaving a Single Lockout Mechanism for Prevention of Firing,” issued Jun.3, 2008; U.S. Pat. No. 7,380,696, entitled “Articulating SurgicalStapling Instrument Incorporating a Two-Piece E-Beam Firing Mechanism,”issued Jun. 3, 2008; U.S. Pat. No. 7,404,508, entitled “SurgicalStapling and Cutting Device,” issued Jul. 29, 2008; U.S. Pat. No.7,434,715, entitled “Surgical Stapling Instrument Having MultistrokeFiring with Opening Lockout,” issued Oct. 14, 2008; U.S. Pat. No.7,721,930, entitled “Disposable Cartridge with Adhesive for Use with aStapling Device,” issued May 25, 2010; U.S. Pat. No. 8,408,439, entitled“Surgical Stapling Instrument with An Articulatable End Effector,”issued Apr. 2, 2013; and U.S. Pat. No. 8,453,914, entitled “Motor-DrivenSurgical Cutting Instrument with Electric Actuator Directional ControlAssembly,” issued Jun. 4, 2013. The disclosure of each of theabove-cited U.S. patents is incorporated by reference herein.

While the surgical staplers referred to above are described as beingused in endoscopic procedures, it should be understood that suchsurgical staplers may also be used in open procedures and/or othernon-endoscopic procedures. By way of example only, a surgical staplermay be inserted through a thoracotomy, and thereby between a patient'sribs, to reach one or more organs in a thoracic surgical procedure thatdoes not use a trocar as a conduit for the stapler. Such procedures mayinclude the use of the stapler to sever and close a vessel leading to alung. For instance, the vessels leading to an organ may be severed andclosed by a stapler before removal of the organ from the thoraciccavity. Of course, surgical staplers may be used in various othersettings and procedures.

Examples of surgical staplers that may be particularly suited for usethrough a thoracotomy are disclosed in U.S. Pat. No. 9,186,142, entitled“Surgical Instrument End Effector Articulation Drive with Pinion andOpposing Racks,” issued Nov. 17, 2015; U.S. Pat. No. 9,717,497, entitled“Lockout Feature for Movable Cutting Member of Surgical Instrument,”issued Aug. 1, 2017; U.S. Pat. No. 9,517,065, entitled “IntegratedTissue Positioning and Jaw Alignment Features for Surgical Stapler,”issued Dec. 13, 2016; U.S. Pat. No. 9,839,421, entitled “Jaw ClosureFeature for End Effector of Surgical Instrument,” issued Dec. 12, 2017;U.S. Pat. No. 9,867,615, entitled “Surgical Instrument with ArticulationLock having a Detenting Binary Spring,” issued Jan. 16, 2018; U.S. Pat.No. 9,622,746, entitled “Distal Tip Features for End Effector ofSurgical Instrument,” issued Apr. 18, 2017; U.S. Pat. No. 10,092,292,entitled “Staple Forming Features for Surgical Stapling Instrument,”issued Oct. 9, 2018; U.S. Pat. No. 9,795,379, entitled “SurgicalInstrument with Multi-Diameter Shaft,” issued Oct. 24, 2017; and U.S.Pat. No. 9,808,248, entitled “Installation Features for SurgicalInstrument End Effector Cartridge,” issued Nov. 7, 2017. The disclosureof each of the above-cited U.S. Patent Publications is incorporated byreference herein.

Additional surgical stapling instruments are disclosed in U.S. Pat. No.8,801,735, entitled “Surgical Circular Stapler with Tissue RetentionArrangements,” issued Aug. 12, 2014; U.S. Pat. No. 8,141,762, entitled“Surgical Stapler Comprising a Staple Pocket,” issued Mar. 27, 2012;U.S. Pat. No. 8,371,491, entitled “Surgical End Effector Having ButtressRetention Features,” issued Feb. 12, 2013; U.S. Pat. No. 9,597,082,entitled “Method and Apparatus for Sealing End-to-End Anastomosis”issued Mar. 21, 2017; U.S. Pat. No. 9,398,911, entitled “Rotary PoweredSurgical Instruments with Multiple Degrees of Freedom,” issued Jul. 26,2016; U.S. Pat. Pub. No. 2013/0206813, entitled “Linear Stapler,”published Aug. 15, 2013; U.S. Pat. Pub. No. 2008/0169328, entitled“Buttress Material for Use with a Surgical Stapler,” published Jul. 17,2008; U.S. Pat. No. 9,848,871, entitled “Woven and Fibrous Materials forReinforcing a Staple Line,” issued Dec. 26, 2017; U.S. Pat. No.9,936,954, entitled “Devices and Methods for Sealing Staples in Tissue”issued Apr. 10, 2018; and U.S. Pat. Pub. No. 2016/0089146, entitled“Radically Expandable Staple Line” published Mar. 31, 2016. Thedisclosure of each of the above-cited U.S. Patents, U.S. PatentPublications, and U.S. patent applications is incorporated by referenceherein.

In some instances, it may be desirable to equip a surgical staplinginstrument with a buttress material to reinforce the mechanicalfastening of tissue provided by staples. Such a buttress may prevent theapplied staples from pulling through tissue and may otherwise reduce arisk of tissue tearing at or near the site of applied staples.

When using a buttress material to reinforce a cut and stapled tissuesite, a buttress applicator may be used to load one or more buttressesonto the end effector for subsequent deployment at the cut and stapledtissue site. To preserve the integrity of the buttresses prior toloading and deployment of buttresses at a tissue site, various packagingis used for the buttresses and/or applicators containing the buttresses.

In some instances, it may be desirable to equip a surgical staplinginstrument with a buttress material to reinforce the mechanicalfastening of tissue provided by staples. Such a buttress may prevent theapplied staples from pulling through tissue and may otherwise reduce arisk of tissue tearing at or near the site of applied staples. Suchbuttress material may be applied to the surgical stapling instrumentwith a buttress applier cartridge. The buttress applier cartridgeretains the buttress material prior to application and releases thebuttress material once applied to the surgical stapling instrument. Anexample of such buttress applier cartridge is disclosed in U.S. Pat.Pub. No. 2017/0056016, entitled “Surgical Stapler Buttress Applicatorwith End Effector Actuated Release Mechanism,” published Mar. 2, 2017,the disclosure of which is incorporated by reference herein.

While various kinds of surgical stapling instruments and associatedcomponents have been made and used, it is believed that no one prior tothe inventor(s) has made or used the invention described in the appendedclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate embodiments of the invention,and, together with the general description of the invention given above,and the detailed description of the embodiments given below, serve toexplain the principles of the present invention.

FIG. 1 depicts a perspective view of an exemplary end effector of asurgical stapler and an exemplary buttress applicator, with the endeffector approaching the buttress applicator;

FIG. 2 depicts a perspective view of the end effector and the buttressapplicator of FIG. 1, with the buttress applicator positioned in the endeffector;

FIG. 3A depicts a cross-sectional end view of a portion of the endeffector of FIG. 1 with the buttress assembly of FIG. 1 applied to theend effector, with tissue positioned between the buttresses in the endeffector, and with the anvil in an open position;

FIG. 3B depicts a cross-sectional end view of the combined end effectorand buttress assembly of FIG. 3A, with tissue positioned between thebuttresses in the end effector, and with the anvil in a closed position;

FIG. 3C depicts a cross-sectional view of a staple and the buttressassembly of FIG. 3A having been secured to the tissue by the endeffector of FIG. 1;

FIG. 4 depicts a perspective view of staples and the buttress assemblyof FIG. 3A having been secured to the tissue by the end effector of FIG.1;

FIG. 5 depicts a perspective view of another exemplary buttressapplicator usable with the end effector of FIG. 1;

FIG. 6 depicts an exploded view of the buttress applicator of FIG. 5;

FIG. 7 depicts a top plan view of the buttress assembly of FIG. 5;

FIG. 8A depicts a cross section view of the buttress assembly of FIG. 7,taken along line 8A-8A of FIG. 7;

FIG. 8B depicts a cross section view of the buttress assembly of FIG. 7,taken along line 8B-8B of FIG. 7;

FIG. 8C depicts a cross section view of the buttress assembly of FIG. 7,taken along line 8C-8C of FIG. 7;

FIG. 8D depicts a cross section view of the buttress assembly of FIG. 7,taken along line 8D-8D of FIG. 7;

FIG. 8E depicts a cross section view of the buttress assembly of FIG. 7,taken along line 8E-8E of FIG. 7;

FIG. 8F depicts a cross section view of the buttress assembly of FIG. 7,taken along line 8F-8F of FIG. 7;

FIG. 8G depicts a cross section view of the buttress assembly of FIG. 7,taken along line 8G-8G of FIG. 7;

FIG. 9 depicts a top plan view of an exemplary buttress assemblyconfigured for use with a circular surgical stapler;

FIG. 10 depicts a cross section view of a staple cartridge of the endeffector of FIG. 1;

FIG. 11 depicts a top plan view of another exemplary buttress assemblyshowing an exemplary asymmetric adhesive distribution;

FIG. 12 depicts a side elevation view of an end effector for a surgicalstapler in an open position, showing the buttress assembly of FIG. 11releasing from the jaws of the end effector;

FIG. 13 depicts a top plan view of another exemplary buttress assemblyshowing another exemplary asymmetric adhesive distribution;

FIG. 14 depicts a side elevation view of the end effector for a surgicalstapler of FIG. 12 in an open position, showing the buttress assembly ofFIG. 13 releasing from the jaws of the end effector;

FIG. 15 depicts a perspective view of an exemplary buttress of thebuttress assembly of the buttress applicator of FIG. 5, showing a meshlayer;

FIG. 16 depicts an enlarged view of the mesh layer of the buttress ofFIG. 15;

FIG. 17 depicts a perspective view of an exemplary buttress assembly ofthe buttress applicator of FIG. 5, showing a film layer with adhesivethereon;

FIG. 18 depicts a cross section view of the buttress of FIG. 15 takenalong line 18-18 as shown in FIG. 15;

FIG. 19 depicts a top perspective view of an exemplary packagingassembly for an applicator having a buttress assembly for use with asurgical stapler;

FIG. 20 depicts a bottom perspective view of the packaging assembly ofFIG. 19;

FIG. 21 depicts a side view of the packaging assembly of FIG. 19, takenalong the long side of the packaging assembly;

FIG. 22 depicts a side view of the packaging assembly of FIG. 19, takenalong the short side of the packaging assembly;

FIG. 23 depicts a cross-section view of the packaging assembly of FIG.21, taken along line 23-23 of FIG. 21;

FIG. 24 depicts a cross-section view of the packaging assembly of FIG.22, taken along line 24-24 of FIG. 22;

FIG. 25 depicts a top perspective view of the packaging assembly of FIG.19, shown without the outer tray and with the foil assembly partiallyopened;

FIG. 26 depicts a partial exploded view of the packaging assembly ofFIG. 19, shown with the outer tray, foil assembly, and inner tray withapplicator separate one another, and with the flap of the inner tray ina closed position;

FIG. 27 depicts a top perspective view of the inner tray and applicatorof FIG. 25, with the applicator partially lifted from the inner tray andthe flap of the inner tray partially lifted;

FIG. 28 depicts a top perspective view of the inner tray and applicatorof FIG. 25, shown with the flap of the inner tray in an open position;

FIG. 29 depicts a top perspective view of the inner tray and applicatorof FIG. 25, shown with the applicator removed from the inner tray;

FIG. 30 depicts a top perspective view of the inner tray of FIG. 25,shown with the desiccant material removed from the inner tray;

FIG. 31 depicts a top perspective view of another exemplary inner trayconfigured for use with the packaging assembly of FIG. 19;

FIG. 32 depicts a bottom perspective view of the inner tray of FIG. 31;

FIG. 33 depicts a schematic view of an exemplary method for packaging anapplicator having a buttress assembly for use with a surgical stapler;

FIG. 34 depicts a perspective view of an exemplary buttress appliercartridge assembly that includes an example of a buttress appliercartridge carrying an example of a buttress assembly for an upper jawand an example of another buttress assembly for a lower jaw;

FIG. 35 depicts a partially exploded perspective view of the buttressapplier cartridge assembly of FIG. 34 showing the buttress assembliesremoved from the buttress applier cartridge;

FIG. 36 depicts a perspective view of the buttress assembly of FIG. 34;

FIG. 37 depicts an exploded perspective view of the buttress assembly ofFIG. 36;

FIG. 38 depicts a bottom view of the buttress assembly of FIG. 34 forthe upper jaw;

FIG. 39 depicts an enlarged bottom view of a distal end portion of thebuttress assembly of FIG. 34 showing a pre-formed slit;

FIG. 40 depicts a top view of the buttress assembly of FIG. 34 for theupper jaw showing an outer profile of the upper jaw thereon;

FIG. 41 depicts a top view of the buttress assembly of FIG. 34 for thelower jaw;

FIG. 42 depicts a bottom view of the buttress assembly of FIG. 34 forthe lower jaw showing an outer profile of the lower jaw thereon;

FIG. 43A depicts a perspective view of an end effector of an exemplarysurgical instrument showing the buttress applier cartridge assembly ofFIG. 34 approaching the end effector with the upper and lower jaws in anopen position;

FIG. 43B depicts the perspective view of the end effector similar toFIG. 43B, but showing the buttress applier cartridge assembly of FIG. 34positioned between the upper and lower jaws in a closed position;

FIG. 43C depicts the perspective view of the end effector similar toFIG. 43B, but showing the buttress assemblies respectively secured tothe upper and lower jaws in the open position;

FIG. 44A depicts a sectional side view of a portion of the end effectorof FIG. 43B with the buttress assemblies of FIG. 34 applied to the endeffector and tissue positioned between the buttress assemblies with theupper and lower jaws in the open position;

FIG. 44B depicts the sectional side view of the portion of the endeffector and the buttress assemblies similar to FIG. 44A, but showingthe upper and lower jaws in the closed position;

FIG. 44C depicts the sectional side view of the buttress assembliessimilar to FIG. 44B, but showing the buttress assemblies secured to thetissue with a staple formed in the tissue;

FIG. 45A depicts a perspective view of the buttress assembly of FIG. 43Csecured to the lower jaw of FIG. 43C and a knife of the end effectorbeing driven distally therethrough;

FIG. 45B depicts the perspective view of the buttress assembly and thelower jaw similar to FIG. 45A, but showing the knife cutting a proximalportion of the buttress assembly while being driven distallytherethrough;

FIG. 45C depicts the perspective view of the buttress assembly and thelower jaw similar to FIG. 45B, but showing the knife cutting anintermediate portion of the buttress assembly while being drivendistally therethrough;

FIG. 45D depicts the perspective view of the buttress assembly and thelower jaw similar to FIG. 45C, but showing the knife cutting a distalportion of the buttress assembly while being driven distallytherethrough;

FIG. 46 depicts a perspective view of staples and the buttress assemblyof FIG. 45D having been secured to the tissue by the end effector asshown in FIG. 44C and cut as shown in FIG. 45D;

FIG. 47 depicts a perspective view of an exemplary buttress appliercartridge assembly that includes an example of a buttress appliercartridge carrying an example of a buttress assembly for an upper jawand an example of another buttress assembly for a lower jaw;

FIG. 48 depicts an exploded perspective view of the buttress appliercartridge assembly of FIG. 47 including a chassis and a platform inaddition to a pair of buttress assemblies;

FIG. 49 depicts a perspective view of the chassis with the platform ofFIG. 48;

FIG. 50 depicts a front perspective view of the platform of FIG. 48;

FIG. 51 depicts a rear perspective view of the platform of FIG. 48;

FIG. 52 depicts an elevational side view of the platform of FIG. 48;

FIG. 53 depicts a top perspective view of a left actuator sled of thebuttress applier cartridge assembly of FIG. 48;

FIG. 54 depicts a bottom perspective view of the left actuator sled ofFIG. 53;

FIG. 55 depicts a top perspective view of a right actuator sled of thebuttress applier cartridge assembly of FIG. 48;

FIG. 56 depicts a bottom perspective view of the right actuator sled ofFIG. 55;

FIG. 57 depicts a perspective view of the chassis and the platform ofFIG. 49 with pairs of left and right actuator sleds of FIG. 53 and FIG.55;

FIG. 58 depicts a cross-sectional view of the chassis, the platform, andthe actuator sleds of FIG. 57 taken along section line 58-58 of FIG. 57;

FIG. 59A depicts a top view of the chassis, the platform, and theactuator sleds of FIG. 57 in a restraint position;

FIG. 59B depicts the top view of the chassis, the platform, and theactuator sleds similar to FIG. 59A, but showing the actuator sleds beingdirected from the restraint position toward a release position;

FIG. 59C depicts the top view of the chassis, the platform, and theactuator sleds similar to FIG. 59B, but showing the actuator sleds inthe release position;

FIG. 60A depicts a perspective view of an end effector of an exemplarysurgical instrument showing the buttress applier cartridge assembly ofFIG. 47 approaching the end effector with the upper and lower jaws in anopen position;

FIG. 60B depicts the perspective view of the end effector similar toFIG. 60A, but showing the buttress applier cartridge assembly of FIG. 47positioned between the upper and lower jaws in a closed position;

FIG. 61 depicts a side sectional view of the end effector and theplatform of the buttress applier cartridge of FIG. 60B in an exemplaryparallel-camber orientation, but with various features hidden forgreater clarity;

FIG. 62 depicts a perspective view of the end effector similar to FIG.60B, but showing the buttress assemblies respectively secured to theupper and lower jaws in the open position and the buttress appliercartridge removed therefrom;

FIG. 63A depicts a sectional side view of a portion of the end effectorof FIG. 60B with the buttress assemblies of FIG. 47 applied to the endeffector and tissue positioned between the buttress assemblies with theupper and lower jaws in the open position;

FIG. 63B depicts the sectional side view of the portion of the endeffector and the buttress assemblies similar to FIG. 63A, but showingthe upper and lower jaws in the closed position;

FIG. 63C depicts the sectional side view of the buttress assembliessimilar to FIG. 63B, but showing the buttress assemblies secured to thetissue with a staple formed in the tissue;

FIG. 64 depicts a perspective view of staples and the buttress assemblyof FIG. 63C having been secured to the tissue by the end effector andcut by a knife;

FIG. 65 depicts the side sectional view of the end effector and theplatform of the buttress applier cartridge similar to FIG. 61, but withthe end effector in an exemplary over-camber orientation;

FIG. 66 depicts the side sectional view of the end effector and theplatform of the buttress applier cartridge similar to FIG. 61, but withthe end effector in an exemplary under-camber orientation;

FIG. 67 depicts a perspective view of an exemplary articulating surgicalstapling instrument;

FIG. 68 depicts a side view of the instrument of FIG. 67;

FIG. 69 depicts a perspective view of an opened end effector of theinstrument of FIG. 67;

FIG. 70A depicts a side cross-sectional view of the end effector of FIG.69, taken along line 70-70 of FIG. 69, with the firing beam in aproximal position;

FIG. 70B depicts a side cross-sectional view of the end effector of FIG.69, taken along line 70-70 of FIG. 69, with the firing beam in a distalposition;

FIG. 71 depicts an end cross-sectional view of the end effector of FIG.69, taken along line 71-71 of FIG. 69;

FIG. 72 depicts an exploded perspective view of the end effector of FIG.69;

FIG. 73 depicts a perspective view of the end effector of FIG. 69,positioned at tissue and having been actuated once in the tissue;

FIG. 74 depicts a perspective view of an alternative version of an endeffector with an angled anvil and an angled cartridge;

FIG. 75 depicts an enlarged, side view of the end effector of FIG. 74;

FIG. 76 depicts an enlarged top view of the end effector of FIG. 74;

FIG. 77 depicts a perspective view of an exemplary surgical staplinginstrument having an end effector with a bent or angled elasticallydeformable tip section;

FIG. 78A depicts an enlarged side view of a distal portion of the endeffector of FIG. 77;

FIG. 78B depicts an enlarged side view of a distal portion of analternate end effector similar to that of FIG. 77;

FIG. 79 depicts a perspective view of an alternative version of an endeffector with an angled anvil and an angled cartridge;

FIG. 80 depicts a perspective view of an alternative version of an endeffector with an angled anvil and an angled cartridge;

FIG. 81 depicts a perspective view of an exemplary end effector of asurgical stapler and an exemplary buttress assembly applicator, with theend effector approaching the buttress assembly applicator;

FIG. 82 depicts a perspective view of the end effector and the buttressassembly applicator of FIG. 81, with the buttress assembly applicatorpositioned in the end effector;

FIG. 83A depicts a cross-sectional end view of a portion of the endeffector of FIG. 81 with the buttress assembly of FIG. 81 applied to theend effector, with tissue positioned between the buttresses in the endeffector, and with the anvil in an open position;

FIG. 83B depicts a cross-sectional end view of the combined end effectorand buttress assembly of FIG. 83A, with tissue positioned between thebuttresses in the end effector, and with the anvil in a closed position;

FIG. 83C depicts a cross-sectional view of a staple and the buttressassembly of FIG. 83A having been secured to the tissue by the endeffector of FIG. 81;

FIG. 84 depicts a perspective view of staples and the buttress assemblyof FIG. 83A having been secured to the tissue by the end effector ofFIG. 81;

FIG. 85 depicts a perspective view of an exemplary buttress assemblyapplicator that includes an example of a buttress assembly applicatorcarrying an example of a buttress assembly for an upper jaw and anexample of another buttress assembly for a lower jaw;

FIG. 86 depicts an exploded perspective view of the buttress assemblyapplicator of FIG. 85 including a chassis and a platform in addition toa pair of buttress assemblies;

FIG. 87 depicts a front perspective view of the chassis of FIG. 86;

FIG. 88 depicts a front perspective view of the platform of FIG. 86;

FIG. 89 depicts a rear perspective view of the platform of FIG. 86;

FIG. 90 depicts an elevational side view of the platform of FIG. 86;

FIG. 91 depicts a top perspective view of a left actuator sled of thebuttress assembly applicator of FIG. 86;

FIG. 92 depicts a bottom perspective view of the left actuator sled ofFIG. 91;

FIG. 93 depicts a top perspective view of a right actuator sled of thebuttress assembly applicator of FIG. 86;

FIG. 94 depicts a bottom perspective view of the right actuator sled ofFIG. 93;

FIG. 95 depicts a perspective view of the chassis and the platform ofFIG. 87 and

FIG. 88 with pairs of left and right actuator sleds of FIG. 91 and FIG.93;

FIG. 96 depicts a cross-sectional view of the chassis, the platform, andthe actuator sleds of FIG. 95 taken along section line 96-96 of FIG. 95;

FIG. 97 depicts a top view of the chassis, the platform, and theactuator sleds of FIG. 95 in a restraint position;

FIG. 98 depicts the top view of the chassis, the platform, and theactuator sleds similar to FIG. 97, but showing the actuator sleds beingdirected from the restraint position toward a release position;

FIG. 99 depicts the top view of the chassis, the platform, and theactuator sleds similar to FIG. 98, but showing the actuator sleds in therelease position;

FIG. 100 depicts a top view of an exemplary end effector of a surgicalinstrument showing the buttress assembly applicator of FIG. 85positioned between the upper and lower jaws of the end effector in aclosed position;

FIG. 101 depicts a bottom view of the end effector of FIG. 100, showingthe buttress assembly applicator of FIG. 85 positioned between the upperand lower jaws of the end effector in a closed position;

FIG. 102 depicts a top view of an exemplary end effector of a surgicalinstrument showing the buttress assembly applicator of FIG. 85positioned between the upper and lower jaws of the end effector in aclosed position;

FIG. 103 depicts a side elevation view of the end effector of FIG. 102,showing the buttress assembly applicator of FIG. 85 in cross-section andpositioned between the upper and lower jaws of the end effector in aclosed position;

FIG. 104 depicts a cross-sectional view of the buttress assemblyapplicator of FIG. 85 taken along line 104-104 of FIG. 85;

FIG. 105 depicts a perspective view of an exemplary alignment featureusable with the buttress assembly applicator of FIG. 85;

FIG. 106 depicts a perspective view of the alignment feature of FIG. 105connected with the chassis of FIG. 86;

FIG. 107 depicts a perspective view of another exemplary alignmentfeature connected with the chassis of the buttress assembly applicatorof FIG. 85, and shown with an end effector with the buttress assemblyapplicator positioned between the upper and lower jaws of the endeffector in a closed position;

FIG. 108 depicts a cross-sectional view of the alignment feature andchassis of the buttress assembly applicator of FIG. 107, shown with thebuttress assembly applicator positioned between the upper and lower jawsof the end effector of FIG. 107 in a closed position;

FIG. 109 depicts a top view of another exemplary buttress assemblyapplicator for use with an end effector of a surgical instrument;

FIG. 110 depicts a side elevation view of an exemplary end effectorhaving a curved tip, showing the buttress assembly applicator of FIG.109 in cross-section and positioned between the upper and lower jaws ofthe end effector in an open position;

FIG. 111 depicts a side elevation view of the end effector of FIG. 110,showing the buttress assembly applicator of FIG. 109 in cross-sectionand positioned between the upper and lower jaws of the end effector in aclosed position;

FIG. 112 depicts a side elevation view of an exemplary end effectorhaving a deformable curved tip, showing an exemplary buttress assemblyapplicator in cross-section and positioned between the upper and lowerjaws of the end effector in an open position;

FIG. 113 depicts a side elevation view of the end effector of FIG. 112,showing the buttress assembly applicator of FIG. 112 in cross-sectionand positioned between the upper and lower jaws of the end effector in aclosed position;

FIG. 114 depicts a top view of the end effector and buttress assemblyapplicator of FIG. 113;

FIG. 115 depicts a top view of another exemplary buttress assemblyapplicator carrying one or more exemplary buttress assemblies forapplying to an end effector of a surgical stapler;

FIG. 116 depicts a top view of the buttress assembly applicator of FIG.115, shown with an end effector positioned within a channel or spacedefined by the buttress assembly applicator prior to clamping;

FIG. 117 depicts a side elevation view of the buttress assemblyapplicator and end effector of FIG. 116, shown with the end effectorpositioned but not clamped;

FIG. 118 depicts a side elevation view of the buttress assemblyapplicator and end effector of FIG. 116, shown with the end effectorpositioned and in a clamped state;

FIG. 119 depicts a perspective view of the buttress assembly applicatorof FIG. 115, shown with the housing assembly removed and with analternate straight tip end effector positioned in an open state over theplatform retaining the buttress assemblies;

FIG. 120 depicts an enlarged perspective view of a proximal portion ofthe combined buttress assembly applicator and end effector of FIG. 119;

FIG. 121 depicts a top view of another exemplary buttress assemblyapplicator for use with an end effector of a surgical instrument;

FIG. 122 depicts a side elevation view of an exemplary end effectorhaving a curved tip, showing the buttress assembly applicator of FIG.121 in cross-section and positioned between the upper and lower jaws ofthe end effector in an open position;

FIG. 123 depicts a side elevation view of the end effector of FIG. 122,showing the buttress assembly applicator of FIG. 121 in cross-sectionand positioned between the upper and lower jaws of the end effector in aclosed position;

FIG. 124 depicts a partial top view of another exemplary buttressassembly applicator showing the platform having a distal perforatedslit;

FIG. 125 depicts a partial top view of another exemplary buttressassembly applicator showing a platform having a distal T-shaped slit;and

FIG. 126 depicts a cross-sectional view of the buttress assemblyapplicator of FIG. 121 taken along line 126-126 of FIG. 121, and shownwithout buttress assemblies.

The drawings are not intended to be limiting in any way, and it iscontemplated that various embodiments of the invention may be carriedout in a variety of other ways, including those not necessarily depictedin the drawings. The accompanying drawings incorporated in and forming apart of the specification illustrate several aspects of the presentinvention, and together with the description serve to explain theprinciples of the invention; it being understood, however, that thisinvention is not limited to the precise arrangements shown.

DETAILED DESCRIPTION

The following description of certain examples of the invention shouldnot be used to limit the scope of the present invention. Other examples,features, aspects, embodiments, and advantages of the invention willbecome apparent to those skilled in the art from the followingdescription, which is by way of illustration, one of the best modescontemplated for carrying out the invention. As will be realized, theinvention is capable of other different and obvious aspects, all withoutdeparting from the invention. Accordingly, the drawings and descriptionsshould be regarded as illustrative in nature and not restrictive.

It should be understood that terms such as “proximal” and “distal” areused herein with reference to a clinician gripping a surgicalinstrument, such as surgical and severing instrument (110) and buttressapplier cartridge assembly (10) discussed below. It will be furtherappreciated that for convenience and clarity, spatial terms such as“upright,” “upside-down,” “upper,” “lower,” “bottom,” and “top” are usedherein with respect to the drawings. However, surgical instruments areused in many orientations and positions, and these terms are notintended to be limiting and absolute.

It is further understood that any one or more of the teachings,expressions, embodiments, examples, etc. described herein may becombined with any one or more of the other teachings, expressions,embodiments, examples, etc. that are described herein. Thefollowing-described teachings, expressions, embodiments, examples, etc.should therefore not be viewed in isolation relative to each other.Various suitable ways in which the teachings herein may be combined willbe readily apparent to those of ordinary skill in the art in view of theteachings herein. Such modifications and variations are intended to beincluded within the scope of the claims.

For clarity of disclosure, the terms “proximal” and “distal” are definedherein relative to a human or robotic operator of the surgicalinstrument. The term “proximal” refers the position of an element closerto the human or robotic operator of the surgical instrument and furtheraway from the surgical end effector of the surgical instrument. The term“distal” refers to the position of an element closer to the surgical endeffector of the surgical instrument and further away from the human orrobotic operator of the surgical instrument. In addition, the terms“upper,” “lower,” “lateral,” “transverse,” “bottom,” “top,” are relativeterms to provide additional clarity to the figure descriptions providedbelow. The terms “upper,” “lower,” “lateral,” “transverse,” “bottom,”“top,” are thus not intended to unnecessarily limit the inventiondescribed herein.

In addition, the terms “first” and “second” are used herein todistinguish one or more portions of the surgical instrument. Forexample, a first assembly and a second assembly may be alternatively andrespectively described as a second assembly and a first assembly. Theterms “first” and “second” and other numerical designations are merelyexemplary of such terminology and are not intended to unnecessarilylimit the invention described herein.

I. Exemplary Buttress Loading and Application

FIGS. 1 and 2 illustrate an exemplary end effector (40) configured toapply a buttress to a tissue site where a cutting and stapling operationis performed. End effector (40) is connected with a shaft assembly (30).End effector (40) comprises an anvil (60), a lower jaw (50), and astaple cartridge (70) received by lower jaw (50).

FIGS. 1 and 2 also illustrate an exemplary buttress applicator (200).Buttress applicator (200) is configured to selectively retain buttressassemblies (100, 110). In the present example, buttress assembly (100)is selectively retained on a top side of applicator (200) and buttressassembly (110) is selectively retained on a bottom side of applicator(200). In some other versions, applicator (200) can be configured suchthat only one buttress assembly (100, 110) is selectively retained bybuttress applicator (200).

To use buttress applicator (200) to load end effector (40) with buttressassemblies (100, 110), the operator would first position applicator(200) and end effector (40) such that end effector (40) is aligned withan open end (202) of applicator (200) as shown in FIG. 1. The operatorwould then advance end effector (40) distally (and/or retract applicator(200) proximally) to position buttress assemblies (100, 110) betweenanvil (60) and staple cartridge (70) as shown in FIG. 2. In order toload buttress assemblies (100, 110) on end effector (40), the operatormay simply close end effector (40) by pivoting anvil (60) toward staplecartridge (70). Closure of end effector (40) results in the distal endsof anvil (60) and staple cartridge (70) bearing against retainingfeatures of buttress applicator (200) that are configured to selectivelyretain buttress assemblies (100, 110) with buttress applicator (200).This contact deflects such retaining features of buttress applicator(200) to thereby permit contact between a surface of anvil (60) andbuttress assembly (100) on one side of buttress applicator (200), and asurface of staple cartridge (70) and buttress assembly (110) on anotherside of buttress applicator (200). Buttress assemblies (100, 110)comprise an adhesive on their respective surfaces such that with endeffector (40) clamping on both buttress assemblies (100, 110), buttressassemblies (100, 110) are adhered respectively to an underside of anvil(60) and a deck surface of staple cartridge (70). End effector (40) maythen be re-opened (i.e., pivoting anvil (60) away from staple cartridge(70)) and pulled away from buttress applicator (200). With retainingfeatures of applicator (200) disengaged from buttress assemblies (100,110), end effector (40) may freely pull buttress assemblies (100, 110)away from buttress applicator (200) as end effector (40) is pulled awayfrom buttress applicator (200). With buttress assemblies (100, 110)loaded on end effector (40), end effector (40) may then be used asdescribed further below with reference to FIGS. 3A-4.

FIGS. 3A-3C show a sequence where an end effector (40) that has beenloaded with buttress assemblies (100, 110) is actuated to drive staples(90) through two apposed layers of tissue (T₁, T₂), with buttressassemblies (100, 110) being secured to the same layers of tissue (T₁,T₂) by staples (90). In particular, FIG. 3A shows layers of tissue (T₁,T₂) positioned between anvil (60) and staple cartridge (70), with anvil(60) in the open position. As shown, anvil (60) comprises staple formingpockets (64). Buttress assembly (100) is adhered, via adhesive, tounderside (65) of anvil (60); while buttress assembly (110) is adhered,via adhesive, to deck (73) of staple cartridge (70). Layers of tissue(T₁, T₂) are thus interposed between buttress assemblies (100, 110).Next, end effector (40) is closed, which drives anvil (60) to the closedposition as shown in FIG. 3B. At this stage, layers of tissue (T₁, T₂)are compressed between anvil (60) and staple cartridge (70), withbuttress assemblies (100, 110) engaging opposite surfaces of tissuelayers (T₁, T₂). End effector (40) is then actuated, whereby a stapledriver (75) drives staple (90) through buttress assemblies (100, 110)and tissue layers (T₁, T₂). As shown in FIG. 3C, crown (92) of drivenstaple (90) captures and retains buttress assembly (110) against layerof tissue (T₂). Deformed legs (94) of staple (90) capture and retainbuttress assembly (100) against layer of tissue (T₁).

It should be understood that a series of staples (90) will similarlycapture and retain buttress assemblies (100, 110) against layers oftissue (T₁, T₂), thereby securing buttress assemblies (100, 110) totissue (T₁, T₂) as shown in FIG. 4. As end effector (40) is pulled awayfrom tissue (90) after deploying staples (90) and buttress assemblies(100, 110), buttress assemblies (100, 110) disengage end effector, suchthat buttress assemblies (100, 110) remain secured to tissue (T₁, T₂)with staples (90). Buttress assemblies (100, 110) thus providestructural reinforcement to the lines of staples (90). As can also beseen in FIG. 4, a knife member (not shown) passes through end effector(40) and in doing so also cuts through a centerline of buttressassemblies (100, 110), separating each buttress assembly (100, 110) intoa corresponding pair of sections, such that each section remains securedto a respective severed region of tissue (T₁, T₂).

In the foregoing example, buttress assembly (100) is sized to spanacross the full width of underside (65) of anvil (60), such that a knifemember (not shown) cuts through buttress assembly (100) during actuationof end effector (40). In some other examples, buttress assembly (100) isprovided in two separate, laterally spaced apart portions, with oneportion being disposed on underside (65) of anvil (60) on one half ofanvil (60) and another portion being disposed on underside (65) of anvil(60) on the other half of anvil (60). In such versions, the knife member(not shown) does not cut through buttress assembly (100) duringactuation of end effector (40).

Likewise, buttress assembly (110) may be sized to span across the fullwidth of deck (73), such that the knife member (not shown) cuts throughbuttress assembly (110) during actuation of end effector (40).Alternatively, buttress assembly (110) may be provided in two separate,laterally spaced apart portions, with one portion being disposed on deck(73) on one half and another portion being disposed on deck (73) on theother half In such versions, the knife member (not shown) does not cutthrough buttress assembly (110) during actuation of end effector (40).

In addition to the foregoing, it should also be understood that any ofthe various buttress assemblies described herein may be furtherconstructed and operable in accordance with at least some of theteachings of U.S. Pat. Pub. No. 2016/0278774, entitled “Method ofApplying a Buttress to a Surgical Stapler,” published Sep. 29, 2016, thedisclosure of which is incorporated by reference herein.

II. Exemplary Buttress Applicator

FIGS. 5 and 6 illustrate an alternate buttress applicator (300) for usewith end effector (40). Buttress applicator (300) comprises a firsthousing portion (302) and a second housing portion (304). Each ofhousing portions (302, 304) connects with a frame (306). A compressionpad (308) is configured to fit within a central portion (310) of frame(306). A first pair of clamp arms (312) are located on a first side offrame (306) between frame (306) and housing portion (302). A second pairof clamp arms (314) are located on a second side of frame (306) betweenframe (306) and housing portion (304). In the present version, clamparms (312) comprise a left clamp arm (311) and a right clamp arm (313).Similarly, clamp arms (314) comprise a left clamp arm (311) and a rightclamp arm (313). Buttress assemblies (316, 318) are located onrespective sides of compression pad (308), and when buttress applicator(300) is fully assembled, pairs of clamp arms (312, 314) selectivelyretain buttress assemblies (316, 318) against compression pad (308). Inthe present example buttress assemblies (316, 318) are the same witheach comprising an adhesive (320) located on a buttress (322) as will bedescribed in greater detail below.

Buttress applicator (300) can be used with end effector (40) in the samemanner as described above with respect to buttress applicator (200). Forinstance, buttress assemblies (316, 318) are loaded to end effector (40)in the same manner as described above where end effector (40) is movedto a closed or clamped position once anvil (60) and lower jaw (50) arepositioned over central portion (310) of frame (308), e.g. asillustrated in FIG. 2. More specifically, the clamping action of endeffector (40) when over buttress assemblies (316, 318) and compressionpad (308) causes anvil (60) and staple cartridge (70) of lower jaw (50)to contact retention features (324) on left clamp arms (311) andretention features (325) on right clamp arms (313). This contact drivesclamp arms (311, 313) laterally away from buttress assemblies (316, 318)thereby disengaging retention features (324, 325) from buttressassemblies (316, 318). With retention features (324, 325) disengaged,depending on the clamping orientation used with end effector (40),adhesive (320) of buttress assembly (316) contacts either underside (65)of anvil (60) or deck (73) of staple cartridge (70), while adhesive(320) of buttress assembly (318) contacts the other of underside (65) ofanvil (60) or deck (73) of staple cartridge (70). This causes buttressassemblies (316, 318) to attach with end effector (40) and remain withend effector (40) as end effector is opened and moved away from buttressapplicator (300). From this point, buttress assemblies (316, 318) may beapplied to a cut and stapled tissue site as described above andillustrated with respect to FIG. 4.

III. Exemplary Buttress Assembly

FIG. 7 illustrates buttress assembly (316), it being understood thatbuttress assembly (318) is identical. As mentioned, buttress assembly(316) comprises buttress (322) and adhesive (320) on one side ofbuttress (322). Buttress (322) comprises one or more layers of material.Where multiple layers are used the layers can be laminated together. Insome examples buttress (322) comprises a mesh layer and one or more filmlayers laminated together. In some other examples buttress (322)comprises one or more film layers without a mesh layer. In view of theteachings herein, other various materials for one or more layers ofbuttress (322) will be apparent to those of ordinary skill in the art.

In the present example, buttress (322) is comprised of an absorbablematerial that is configured to be completed absorbed by the patient'sbody when used to reinforce a cut and staple site. In some examples,buttress (322) is comprised of polyglactin 910, which is 90% glycolideand 10% L-lactide. An example of polyglactin 910 is manufactured byEthicon Inc. under the brand name Vicryl®. In view of the teachingsherein, other absorbable synthetic materials for use with buttress (322)will be apparent to those of ordinary skill in the art.

A. Exemplary Adhesive Placement

Buttress (322) comprises a first surface (326) and a second surface(328) opposite to first surface (326). Buttress also includes a proximalend (330) and a distal end (332). As seen with reference to FIGS. 4 and5, buttress assembly (316) is retained by applicator (300) such thatwhen loading buttress assemblies (316, 318) to end effector (40), distalend (332) of buttress (322) aligns with a distal end (41) of endeffector (40). With this configuration, buttress (322) defines a lengthextending from proximal end (330) to distal end (332). Buttress (322)further defines a longitudinal axis (A1) that extends between proximalend (330) and distal end (332). Buttress (322) includes a first edgeregion (334), a second edge region (336), and a center region (338)between and separating first edge region (334) and second edge region(336). Buttress (322) defines a width extending orthogonal to its lengthas defined above, where its width extends from first edge region (334)across center region (338) and through second edge region (336).

In the present example, adhesive (320) is applied onto first surface(326) of buttress (322). In some other versions of buttress assembly(316) adhesive (320) can be applied onto second surface (328) ofbuttress (322). Returning to the present example, adhesive (320) extendsfrom proximal end (330) to distal end (332) of buttress (322). Moreover,in the present example, adhesive (320) extends continuously or in anuninterrupted manner. As shown in FIG. 7, adhesive (320) is locatedalong first edge region (334) and second edge region (336), with centerregion (338) being substantially free of adhesive (320). As will bedescribed further below, adhesive (320) is applied to buttress in amanner such that adhesive (320) comprises a height such that adhesive(320) is proud of buttress (322). The height of adhesive (320) isconfigured to facilitate adhesive (320) making good contact with eitherunderside (65) of anvil (60) of end effector (40) or deck (73) of staplecartridge (70) of end effector (40) depending on the orientation of endeffector (40) when loading buttress assembly (316).

The continuous nature of adhesive (320) along with the height ofadhesive (320) act to seal the edges of buttress (322) to the part ofend effector (40) to which buttress (322) attaches. For instance, wherebuttress assembly (316) is on anvil (60) side of end effector (40), thecontinuous adhesive (320) with its height creates a seal along the edgesof buttress (322) of buttress assembly (316) where adhesive (320)contacts underside (65) of anvil (60). Similarly, where buttressassembly (318) is on staple cartridge (70) side of end effector (40),the continuous adhesive (320) with its height creates a seal along theedges of buttress (322) of buttress assembly (318) where adhesive (320)contacts deck (73) of staple cartridge (70). With this sealingattachment, in use the amount of moisture that can reach buttressassembly (316) is reduced. For instance, moisture is sealed out of theinside of buttress assembly (316), which keeps at least a portion ofadhesive (320) free from moisture. By controlling moisture migration inthis manner, buttress assemblies (316, 318) can have longer attachmenttimes with end effector (40). This can give users greater lengths oftime to position and manipulate end effector (40) before executing acutting and stapling action, thereby applying buttresses (322) asreinforcing structures to the cut and stapled site.

Referring to FIG. 9, which shows exemplary buttress assembly (416), thesealing attachment discussed above can also apply to buttress assembliesconfigured for use with circular surgical staplers. For instance,buttress assembly (416) comprises a circular shape and is configured foruse with a circular surgical stapler. Buttress assembly (416) comprisesbuttress (422) and adhesive (420). As shown, adhesive (420) is appliedin a concentric circular pattern on buttress (422). In this manner,outer adhesive ring (424) creates sealing attachment with the endeffector components of a circular stapler as those of ordinary skill inthe art will understand in view of the teachings herein. This slows orprevents moisture from contacting a majority of buttress assembly (416),including inner adhesive ring (426), in the same or similar manner asdescribed above with respect to buttress assemblies (316, 318).

B. Exemplary Adhesive Pattern and Distribution

Referring still to FIG. 7, and now also FIGS. 8A-8G, other detailsconcerning buttress assemblies (316, 318) are described below relatingto adhesive (320) and its pattern and amount. As shown in FIG. 7, centerregion (338) of buttress (322) comprises slits (340). In the illustratedversion, slits (340) include a proximal slit (342), a distal slit (344),and an intermediate slit (346) between proximal and distal slits (342,344). Slits (340) are configured to promote or facilitate cutting andseparating buttress (322) into substantially equal halves during acutting and stapling operation as discussed above. As shown in thepresent example, buttress assemblies (316, 318) comprise slits (342,344) at both proximal end (330) and distal end (332) of buttress (322),where these slits (342, 344) extend all the way to the respective endsof buttress (322). This configuration helps ensure full cutting andseparation of buttress (322) at its ends during a cut and staplesequence. Also in the present example, longitudinal axis (A1) passesthrough slits (340), and on each side of center region (338), adhesive(320) defines a pattern that is substantially symmetrical with the otherside about longitudinal axis (A1).

Now considering adhesive (320) as applied to first edge region (334),adhesive (320) comprises a first bead (348) and a second bead (350).Each bead of adhesive (348, 350) extends generally from proximal end(330) of buttress (322) to distal end (332) of buttress (322). As shownin FIGS. 8A-8G, first bead of adhesive (348) partially overlaps secondbead of adhesive (350) along at least a portion of a length of buttress(322). Still in other areas, first bead of adhesive (348) is spacedapart from second bead of adhesive (350) along at least a portion of alength of buttress (322). As shown best in FIG. 7, second bead ofadhesive (350) extends further proximally compared to first bead ofadhesive (348). Furthermore, first and second beads of adhesive (348,350) extend distally to substantially the same extent relative tobuttress (322).

Now considering adhesive (320) as applied to second edge region (336),adhesive (320) comprises a third bead (352) and a fourth bead (354).Each bead of adhesive (352, 354) extends generally from proximal end(330) of buttress (322) to distal end (332) of buttress (322). As shownin FIGS. 8A-8G, third bead of adhesive (352) partially overlaps fourthbead of adhesive (354) along at least a portion of a length of buttress(322). Still in other areas, third bead of adhesive (352) is spacedapart from fourth bead of adhesive (354) along at least a portion of alength of buttress (322). As shown best in FIG. 7, fourth bead ofadhesive (354) extends further proximally compared to third bead ofadhesive (352). Furthermore, third and fourth beads of adhesive (352,354) extend distally to substantially the same extent relative tobuttress (322). As mentioned above, first and second beads of adhesive(348, 350) are collectively symmetrical with third and fourth beads ofadhesive (352, 354) about longitudinal axis (A1) defining a centerlineof buttress (322).

Considering now adhesive (320) as applied at proximal and distal ends(330, 332) of buttress (322), in the present example, an unevendistribution of adhesive (320) is used. This uneven distribution ofadhesive (320) comprises more adhesive at distal end (332) of buttress(322) than at proximal end (330) of buttress (322). In the presentexample, this is the case when comparing buttress (322) prior to cuttinginto halves or when comparing halves of cut buttress (322). This unevendistribution of adhesive (320) is created at least in part by secondbead of adhesive (350) and fourth bead of adhesive (354) extendingfurther proximally into proximal end (330) of buttress (322) compared torespective first bead of adhesive (348) and third bead of adhesive(352). And further on distal end (332) both first and second beads ofadhesive (348, 350) and both third and fourth beads of adhesive (352,354) extend to the same extent. This arraignment results in moreadhesive (320) at distal end (332) compared to proximal end (330) ofbuttress (322). In examples like the present one where more adhesive(320) is present at distal end (332) of buttress (322), this helpsbuttress (322) stay attached and aligned to and with the respectiveparts of end effector (40) when aggressively manipulating end effector(40), i.e. when piercing through ostomies, sliding axially onto tissue,etc.

As mentioned, distal end (332) of buttress (322) aligns with distal end(41) of end effector (40). Because distal end (41) of end effector (40)is the first part of end effector (40) to contact tissue whenpositioning end effector (40), distal end (41) of end effector (40) canbe subject to greater forces in use compared to the proximal end of endeffector (40). Because of this, having stronger attachment of buttressassemblies (316, 318) at distal end (41) of end effector (40) can bebeneficial to maintaining attachment and alignment of buttressassemblies (316, 318) with respective parts of end effector (40). Oneway to achieve such stronger attachment at distal end (332) of buttressassemblies (316, 318) is by having more adhesive placed at distal end(332) of buttress (322). More adhesive (320) can be achieved by a volumebasis, a mass basis, a surface area or contact area basis, or an areadensity basis. In view of the teachings herein, other ways to providefor stronger attachment between buttress assemblies (316, 318) at theirdistal ends (332) and respective components at distal end (41) of endeffector (40) will be apparent to those of ordinary skill in the art inview of the teaching herein.

In use, releasing of buttress (322) from end effector (40) is also aconsideration. Buttress (322) should release from end effector (40) suchthat it is transferred to the tissue cut and stapled site so buttress(322) can provide structural reinforcement to the site. With theclamping action of the jaws of end effector (40), there is a largeaperture or opening of distal end (41) after end effector (40) has beenfired and is being opened to remove end effector (40) from a cut andstapled site. This motion of distal end (41) with the large aperture oropening enables release of buttress (322) from distal end (41) of endeffector (40) even with buttress (322) initially having more adhesive(320) at its distal end (332) compared to its proximal end (330).

The described adhesive pattern and distribution above can be seen inFIGS. 8A-8G that show cross sections of adhesive (320) along the lengthof buttress (322). For instance, FIG. 8A is taken along proximal end(330) of buttress assembly (316). As shown in FIG. 8A, second and fourthbeads of adhesive (350, 354) extend further proximally than first andthird beads of adhesive (348, 352). Also evident from FIG. 8A isproximal slit (342). Furthermore, as shown in FIGS. 7 and 8A, buttress(322) comprises a taper at its proximal end (330), where a width ofbuttress (322) decreases as buttress (322) extends proximally.

FIG. 8B illustrates an area where first bead of adhesive (348) partiallyoverlaps second bead of adhesive (350), and similarly an area wherethird bead of adhesive (352) partially overlaps fourth bead of adhesive(354). As shown in FIG. 8B as well as the other views of FIGS. 8A and8C-8G, adhesive (320) is symmetrical about longitudinal axis (A1).

FIG. 8C illustrates how first bead of adhesive (348) is spaced apartfrom second bead of adhesive (350) when examining adhesive (320) furtherdistally along the length of buttress (322). Similarly, third bead ofadhesive (352) is spaced apart from fourth bead of adhesive (354). Atthe location shown in FIG. 8C, center region (338) lacks any slit in thepresent example.

FIG. 8D illustrates the adhesive pattern and distribution at anapproximate middle of the length of buttress assemblies (316, 318). Hereagain, first bead of adhesive (348) partially overlaps second bead ofadhesive (350), and similarly third bead of adhesive (352) partiallyoverlaps fourth bead of adhesive (354). When comparing FIG. 8D with 8B,in the present example, the degree of adhesive overlap is greater at theapproximate middle of the length of buttress assemblies (316, 318) asevident by the larger width of the overlap.

FIG. 8E illustrates a similar arrangement as shown in FIG. 8C. The onlydifference with FIG. 8E is that slit (346) splits buttress (322) intohalves along the length shown in FIG. 8E, whereas center region (338)lacks any slit along the length shown in FIG. 8C.

FIG. 8F illustrates a similar arrangement as shown in FIG. 8D. The onlydifference with FIG. 8F is that center region (338) comprises distalslit (344) along the length shown in FIG. 8F, whereas center region(338) comprises intermediate slit (346) along the length shown in FIG.8D.

FIG. 8G illustrates adhesive (320) at distal end (332) of buttress(322). As seen in FIGS. 7 and 8G, second bead of adhesive (350) extendsaway from center region (338) at distal end (332) of buttress (322).Similarly, fourth bead of adhesive (354) extends away from center region(338) at distal end (332) of buttress (322). In the present example,second bead of adhesive (350) extends away from center region (338) suchthat second bead of adhesive (350) connects with or contacts first beadof adhesive (348) at distal end (332) of buttress (322). Also, fourthbead of adhesive (354) extends away from center region (338) such thatfourth bead of adhesive (354) connects with or contacts third bead ofadhesive (352) at distal end (332) of buttress (322). As also shown inFIG. 8G, buttress (322) comprises a gap (356) at distal end (332), wheregap (356) aligns with center region (338). Referring to FIG. 7, a gap(358) is also present at proximal end (330) in the present example.

C. Exemplary Adhesive Heights

As mentioned above adhesive height is a feature or attribute thatfacilitates attachment and release of buttress (322) with anvil (60) andstaple cartridge (70) components of end effector (40). In this respectheight of adhesive (320) is understood as the distance adhesive (320)protrudes from the surface of buttress (322) to which it is applied. Inthe present example, beads of adhesive (348, 350, 352, 354) have aminimum height. In one example, the minimum height is configured toapproximate, match, or exceed the height of pocket extenders (74) ondeck (73) of staple cartridge (70). FIG. 10 illustrates a cross sectionview of a version of staple cartridge (70) having pocket extenders (74).Pocket extenders (74) protrude above deck (73) of staple cartridge (70)and can assist in gripping tissue captured by end effector (40). Byconfiguring adhesive beads (348, 350, 352, 354) with a minimum heightthat approximates, matches, or exceeds the distance that pocketextenders (74) protrude above deck (73), adhesive (320) can be incontact with the surface of pocket extenders (74) but also with thesurface of deck (73) between pocket extenders (74). This provides forgood attachment of one of buttress assemblies (316, 318) with staplecartridge (70) during the buttress loading process and increasesretention of buttress (322) to this component of end effector (40) whenworking with and positioning end effector (40). While pocket extenders(74) are used with the version of staple cartridge (70) shown in FIG.10, in other versions of staple cartridge (70) pocket extenders (74) areomitted such that deck (73) is flat with the exception of the openingsfor driving staples (90).

In one example, beads of adhesive (348, 350, 352, 354) have a heightbetween about 0.010 inches (0.254 mm) and about 0.050 inches (1.27 mm).In another example, beads of adhesive (348, 350, 352, 354) have a heightbetween about 0.016 inches (0.4064 mm) and about 0.030 inches (0.762mm). In view of the teachings herein, other heights for beads ofadhesive (348, 350, 352, 354) will be apparent to those of ordinaryskill in the art.

In another example of a minimum adhesive height, beads of adhesive (348,350, 352, 354) have a minimum height that is configured to approximate,match, or exceed the depth of staple forming pockets (64) of anvil (60).By way of reference, staple forming pockets (64) are illustrated inFIGS. 3A-3B. By configuring adhesive beads (348, 350, 352, 354) with aminimum height that approximates, matches, or exceeds the depth ofstaple forming pockets (64), adhesive (320) can be in contact withunderside (65) of anvil (60) but also extend into staple forming pockets(64). This provides for good attachment of one of buttress assemblies(316, 318) with anvil (60) during the buttress loading process andincreases retention of buttress (322) to this component of end effector(40) when working with and positioning end effector (40).

In some examples, like end effector (40) having anvil (60) and staplecartridge (70), the depth of staple forming pockets (64) of anvil (60)can be different from the distance that pocket extenders (74) protrudeabove deck (73) of staple cartridge (70). In such instances wherebuttress assemblies (316, 318) are identical, beads of adhesive (348,350, 352, 354) can be configured such that the minimum height is basedon the larger distance. For instance in an example where staple formingpockets (64) are shallower than pocket extenders (74)—such that stapleforming pockets (64) have a depth that is less than the distance pocketextenders (74) protrude from deck (73)—beads of adhesive (348, 350, 352,354) can be configured such that the minimum height is based on thedistance pocket extenders (74) protrude above deck (73) as that is thegreater distance compared with the depth of staple forming pockets (64)of anvil (60). Still in other versions, buttress assemblies (316, 318)could be configured differently in terms of adhesive heights toconfigure the adhesive heights specific to either the anvil side orstaple cartridge side of the end effector. However, by setting theminimum adhesive height based on the greater distance, the goodattachment and retention results can be obtained in a symmetricconfiguration that allows applicator (300) to be universal and notspecific to any particular side of the end effector when loading abuttress assembly thereto.

In the present example where adhesive (320) is applied in beads, variousadhesive heights can be achieved in a more efficient manner compared toapplying a uniform spray of adhesive across the entire surface ofbuttress (322). This efficiency is realized both in terms of materialusage and cost. Additionally, while the above examples show and describeadhesive height with respect to linear style buttress assemblies (316,318), adhesive height can be controlled and configured in the same wayswith circular buttresses such as buttress assembly (416) of FIG. 9.

D. Exemplary Asymmetric Adhesive Distributions

When loading buttress assemblies to an end effector and applying them toa tissue cut and stapled site, another consideration, besides goodattachment and retention of the buttress assemblies with the endeffector, is release of the buttress assemblies from the end effectorafter executing a cut and staple operation. For instance, if release ispoor, buttress assemblies can adhere to the end effector instead oftransferring to the tissue, or buttress assemblies can bunch or foldinstead of laying flat and smooth against the tissue site. Referring nowto FIGS. 11-14, buttress assemblies are shown that use asymmetricadhesive distributions to achieve both desired attachment and retentionand also release of buttress assemblies.

FIG. 11 illustrates a buttress assembly (516) having an asymmetricadhesive distribution. Buttress assembly (516) is configured similar tobuttress assemblies (316, 318) described above, except with a differentadhesive application pattern. Accordingly, two buttress assemblies (516)can be used in place of buttress assemblies (316, 318) described above.This includes being used in place of buttress assemblies (316, 318) withapplicator (300) and end effector (40).

In the present example of FIG. 11, buttress assembly (516) comprisesbuttress (522) and adhesive (520) on one side of buttress (522).Buttress (522) comprises a first surface (526) and a second surfaceopposite to first surface (526). Buttress also includes a proximal end(530) and a distal end (532). As with buttress assemblies (316, 318)when buttress assembly (516) is attached with end effector (40) distalend (532) of buttress (522) aligns with a distal end (41) of endeffector (40). With this configuration, buttress (522) defines a lengthextending from proximal end (530) to distal end (532). Buttress (522)further defines a longitudinal axis (A2) that extends between proximalend (530) and distal end (532). Buttress (522) includes a first edgeregion (534), a second edge region (536), and a center region (538)between and separating first edge region (534) and second edge region(536). Buttress (522) defines a width extending orthogonal to its lengthas defined above, where its width extends from first edge region (534)across center region (538) and through second edge region (536).

In the present example, adhesive (520) is applied onto first surface(526) of buttress (522). Adhesive (520) extends from proximal end (530)to distal end (532) of buttress (522). Moreover, in the present example,at least a portion of adhesive (520) extends continuously or in anuninterrupted manner. Adhesive (520) is located along first edge region(534) and second edge region (536), with center region (538) beingsubstantially free of adhesive (520). As described above, adhesive (520)is applied to buttress in a manner such that adhesive (520) comprises aheight such that adhesive (520) is proud of buttress (522). The heightof adhesive (520) is configured to facilitate adhesive (520) making goodcontact with either underside (65) of anvil (60) of end effector (40) ordeck (73) of staple cartridge (70) of end effector (40) depending on theorientation of end effector (40) when loading buttress assembly (516)onto end effector (40) using applicator (300).

The continuous nature of adhesive (520) along with the height ofadhesive (520) act to seal the edges of buttress (522) to the part ofend effector (40) to which buttress (522) attaches. With this sealingattachment, in use the amount of moisture that can reach buttressassembly (516) is reduced. By controlling moisture migration in thismanner, buttress assembly (516) can have longer attachment times withend effector (40). This can give users greater lengths of time toposition and manipulate end effector (40) before executing a cutting andstapling action, thereby applying buttresses (522) as reinforcingstructures to the cut and stapled site.

Referring still to FIG. 11, center region (538) of buttress (522)comprises slits (540), which are structurally and functionally the sameas slits (340) of buttress assemblies (316, 318). In the illustratedversion, slits (540) include a proximal slit (542), a distal slit (544),and an intermediate slit (546) between proximal and distal slits (542,544). In the present example, longitudinal axis (A2) passes throughslits (540), and on each side of center region (538), adhesive (520)defines a pattern that is asymmetrical with the other side aboutlongitudinal axis (A2). Adhesive (520) is further asymmetrical about alateral axis (A3) that extends orthogonal relative to longitudinal axis(A2) through a midpoint of buttress assembly (516) as measured betweenproximal and distal ends (330, 332).

Now considering adhesive (520) as applied to first edge region (534),adhesive (520) comprises a first bead (548) and a second bead (550).Each bead of adhesive (548, 550) extends generally from proximal end(530) of buttress (522) to distal end (532) of buttress (522). Firstbead of adhesive (548) partially overlaps second bead of adhesive (550)along at least a portion of a length of buttress (522), specifically inthe present example near proximal end (530) and near a middle area alongthe length of buttress (522) as shown in FIG. 11. In other areas, firstbead of adhesive (548) is spaced apart from second bead of adhesive(550) along at least a portion of a length of buttress (522). Secondbead of adhesive (550) extends further proximally compared to first beadof adhesive (548). Furthermore, first and second beads of adhesive (548,550) extend distally to substantially the same extent relative tobuttress (522). First bead of adhesive (548) is discontinuous neardistal end (532) of buttress (522), where there is a space or gap (560)in first bead of adhesive (548). In contrast, second bead of adhesive(550) extends continuously from proximal end (530) to distal end (532)of buttress (522).

Now considering adhesive (520) as applied to second edge region (536),adhesive (520) comprises a third bead (552) and a fourth bead (554).Each bead of adhesive (552, 554) extends generally from proximal end(530) of buttress (522) to distal end (532) of buttress (522). Thirdbead of adhesive (552) partially overlaps fourth bead of adhesive (554)along at least a portion of a length of buttress (522), specifically inthe present example near distal end (532) and near a middle area alongthe length of buttress (522). In other areas, third bead of adhesive(552) is spaced apart from fourth bead of adhesive (554) along at leasta portion of a length of buttress (522). Fourth bead of adhesive (554)extends further proximally compared to third bead of adhesive (552).Furthermore, third and fourth beads of adhesive (552, 554) extenddistally to substantially the same extent relative to buttress (522). Inthe present example, while third and fourth beads of adhesive (552, 554)have different shapes or patterns, both extend continuously fromproximal end (530) to distal end (532) of buttress (522).

As mentioned above, first and second beads of adhesive (548, 550) arecollectively asymmetrical with third and fourth beads of adhesive (552,554) about longitudinal axis (A2) and lateral axis (A3). As alsomentioned above, buttress (522) is configured to be cut into two halvesabout a longitudinal centerline of buttress (522). A first half of cutbuttress (522) would include first edge region (534) and about half ofcenter region (538), while a second half of cut buttress (522) wouldinclude second edge region (536) and about the other half of centerregion (538).

Considering now adhesive (520) as applied at proximal and distal ends(530, 532) of respective halves of buttress (522), in the presentexample, an uneven distribution of adhesive (520) is used. With respectto the first half of a cut buttress (522), there is more adhesive (520)at proximal end (530) of buttress (522) than at distal end (532) ofbuttress (522). However, with respect to the second half of a cutbuttress (522), there is more adhesive (520) at distal end (532) ofbuttress (522) than at proximal end (530) of buttress (522). Referringto FIG. 11, these differences in adhesive (520) amounts are shown bycircled regions, where first regions (R1) have more adhesive (520) thansecond regions (R2).

When using two buttress assemblies (516), when applied to end effector(40), each buttress assembly (516) is oriented opposite the other withfirst surfaces (526) containing adhesive (520) facing away from eachother. In this arrangement, first edge region (534) of buttress assembly(516) attached with anvil (60) will be above and aligned with secondedge region (536) of buttress assembly (516) attached with staplecartridge (70). Similarly, second edge region (536) of buttress assembly(516) attached with anvil (60) will be above and aligned with first edgeregion (534) of buttress assembly (516) attached with staple cartridge(70). In this arrangement, first regions (R1) having more adhesive (520)will be oriented opposite and aligned with second regions (R2) havingless adhesive (520). By way of example only, at proximal end (530),buttress assembly (516) attached with anvil (60) will have first region(R1) positioned opposite and aligned with second region (R2) of theother buttress assembly (516) that is attached with staple cartridge(70). Likewise, and still at proximal end (530), buttress assembly (516)attached with anvil (60) will have second region (R2) positionedopposite and aligned with first region (R1) of the other buttressassembly (516) that is attached with staple cartridge (70). At distalend (532), buttress assembly (516) attached with anvil (60) will havesecond region (R2) positioned opposite and aligned with first region(R1) of the other buttress assembly (516) that is attached with staplecartridge (70). Likewise, and still at distal end (532), buttressassembly (516) attached with anvil (60) will have first region (R1)positioned opposite and aligned with second region (R2) of the otherbuttress assembly (516) that is attached with staple cartridge (70).

When considering buttress assembly (516) before it is cut in halves,there are two first regions (R1) in the present example for buttressassembly (516) attached on anvil (60) side of end effector (40). Onesuch first region (R1) is within first edge region (534) at proximal end(530), and the other is within second edge region (536) at distal end(532). This is the same with respect to buttress assembly (516) attachedon staple cartridge (70) side of end effector (40). These first regions(R1) with the more adhesive help buttresses (522) stay attached andaligned to and with the respective parts of end effector (40) whenaggressively manipulating end effector (40), i.e. when piercing throughostomies, sliding axially onto tissue, etc. Furthermore, becausebuttress assemblies (516) are not yet cut, these areas of greateradhesive work to attach and retain the entire buttress assembly (516)with its respective parts of end effector (40).

Still considering buttress assembly (516) before it is cut in halves,there are two second regions (R2) in the present example for buttressassembly (516) attached on anvil (60) side of end effector (40). Onesuch second region (R2) is within first edge region (534) at proximalend (530), and the other is within second edge region (536) at distalend (532). This is the same with respect to buttress assembly (516)attached on staple cartridge (70) side of end effector (40). Thesesecond regions (R2) with the less adhesive help buttresses (522)properly release from end effector (40) after a cut and stapleoperation. However, because buttress assemblies (516) are not yet cut,these areas of lower adhesive are still attached and retained on theirrespective parts of end effector (40) in part due to those first regions(R1) with greater adhesive (520) as discussed above.

Referring to FIG. 12, a side view of end effector (40) is shown duringan exemplary opening operation after a cut and staple action, and thusafter buttress assembly (516) has been cut into halves. With theasymmetric distribution of adhesive (520) described above, when endeffector (40) is opened after cutting and stapling, having first regions(R1) with more adhesive (520) opposite second regions (R2) with lessadhesive (520) reduces the adhesive attachment to the respectivesurfaces on anvil (60) and staple cartridge (70). For instance, uponopening end effector (40) after a cutting and stapling action, secondregions (R2) with less adhesive (520) detach or release from endeffector (40) prior to first regions (R1) with the greater adhesive(520). As mentioned above, prior to cutting buttress assembly (516) intohalves, buttress assembly (516) operates as a unit and thus the combinedfirst areas (R1) with greater adhesive provide for attachment andretention of buttress assembly (516). However, this changes oncebuttress assembly (516) is cut into halves as second regions (R2) willnow release from end effector (40).

For ease of illustration, FIG. 12 shows end effector (40) loaded with asingle buttress assembly (516) on staple cartridge (70) side, where acut and staple operation has occurred such that the knife of endeffector (40) has cut buttress assembly (516) into halves. In FIG. 12,first half (562) and second half (564) of buttress assembly (516) areshown with their attachment and release profiles. First half (562)represents first edge region (534) and half of center region (538) asillustrated in FIG. 11. As shown, first half (562) has first region (R1)with the greater adhesive (520) located at the proximal end of staplecartridge (70). Thus when opening end effector (40) initially, firsthalf (562) remains attached with staple cartridge (70) near the proximalend of staple cartridge (70). First half (562) has second region (R2)with less adhesive (520) located at the distal end of staple cartridge(70). Thus when opening end effector (40) initially, first half (562)releases from staple cartridge (70) near the distal end of staplecartridge (70). Second half (564) represents second edge region (536)and half of center region (538) as illustrated in FIG. 11. As shown,second half (564) has first region (R1) with the greater adhesive (520)located at the distal end of staple cartridge (70). Thus when openingend effector (40) initially, second half (564) remains attached withstaple cartridge (70) near the distal end of staple cartridge (70).Second half (564) has second region (R2) with less adhesive (520)located at the proximal end of staple cartridge (70). Thus when openingend effector (40) initially, second half (564) releases from staplecartridge (70) near the proximal end of staple cartridge (70). Thispattern of attachment and release post cutting and stapling would alsobe evident on anvil (60) side of end effector (40) for buttress assembly(516) loaded onto anvil (60).

Other than the disparity in adhesive (520) described above, anotherfactor that contributes to the release of buttress assembly (516) fromend effector (40) is the large aperture or large motion of distal end(41) of end effector (40) when being opened after a cut and stapleaction. This large range of motion for distal end (41) of end effector(40) also works with the fact that after the cut and staple action twoopposing halves of two buttress assemblies (516) are now stapledtogether with tissue therebetween. Accordingly, these factors providefor release of buttress assemblies (516) even at first regions (R1) thathave greater adhesive that was adhering buttress assemblies (516) torespective parts of end effector (40).

Referring now to FIGS. 13 and 14, FIG. 13 illustrates a buttressassembly (616) having another exemplary asymmetric adhesivedistribution. Buttress assembly (616) is configured similar to buttressassemblies (316, 318) described above, except with a different adhesiveapplication pattern. Accordingly, two buttress assemblies (616) can beused in place of buttress assemblies (316, 318) described above. Thisincludes being used in place of buttress assemblies (316, 318) withapplicator (300) and end effector (40).

In the present example of FIG. 13, buttress assembly (616) comprisesbuttress (622) and adhesive (620) on one side of buttress (622).Buttress (622) comprises a first surface (626) and a second surfaceopposite to first surface (626). Buttress also includes a proximal end(630) and a distal end (632). As with buttress assemblies (316, 318)when buttress assembly (616) is attached with end effector (40) distalend (632) of buttress (622) aligns with a distal end (41) of endeffector (40). With this configuration, buttress (622) defines a lengthextending from proximal end (630) to distal end (632). Buttress (622)further defines a longitudinal axis (A4) that extends between proximalend (630) and distal end (632). Buttress (622) includes a first edgeregion (634), a second edge region (636), and a center region (638)between and separating first edge region (634) and second edge region(636). Buttress (622) defines a width extending orthogonal to its lengthas defined above, where its width extends from first edge region (634)across center region (638) and through second edge region (636).

In the present example, adhesive (620) is applied onto first surface(626) of buttress (622). Adhesive (620) extends from proximal end (630)to distal end (632) of buttress (622). Moreover, in the present example,at least a portion of adhesive (620) extends continuously or in anuninterrupted manner. Adhesive (620) is located along first edge region(634) and second edge region (636), with center region (638) beingsubstantially free of adhesive (620). As described above, adhesive (620)is applied to buttress in a manner such that adhesive (620) comprises aheight such that adhesive (620) is proud of buttress (622). The heightof adhesive (620) is configured to facilitate adhesive (620) making goodcontact with either underside (65) of anvil (60) of end effector (40) ordeck (73) of staple cartridge (70) of end effector (40) depending on theorientation of end effector (40) when loading buttress assembly (616)onto end effector (40) using applicator (300).

The continuous nature of adhesive (620) along with the height ofadhesive (620) act to seal the edges of buttress (622) to the part ofend effector (40) to which buttress (622) attaches. With this sealingattachment, in use the amount of moisture that can reach buttressassembly (616) is reduced. By controlling moisture migration in thismanner, buttress assembly (616) can have longer attachment times withend effector (40). This can give users greater lengths of time toposition and manipulate end effector (40) before executing a cutting andstapling action, thereby applying buttresses (622) as reinforcingstructures to the cut and stapled site.

Referring still to FIG. 13, center region (638) of buttress (622)comprises slits (640), which are structurally and functionally the sameas slits (340) of buttress assemblies (316, 318). In the illustratedversion, slits (640) include a proximal slit (642), a distal slit (644),and an intermediate slit (646) between proximal and distal slits (642,644). In the present example, longitudinal axis (A4) passes throughslits (640), and on each side of center region (638), adhesive (620)defines a pattern that is asymmetrical with the other side aboutlongitudinal axis (A4). Adhesive (620) is further asymmetrical about alateral axis (A5) that extends orthogonal relative to longitudinal axis(A4) through a midpoint of buttress assembly (616) as measured betweenproximal and distal ends (630, 632).

Now considering adhesive (620) as applied to first edge region (634),adhesive (620) comprises a first bead (648) and a second bead (650).Each bead of adhesive (648, 650) extends generally from proximal end(630) of buttress (622) to distal end (632) of buttress (622). Firstbead of adhesive (648) partially overlaps second bead of adhesive (650)along at least a portion of a length of buttress (622), specifically inthe present example near proximal end (630), near a middle area alongthe length of buttress (622), and near distal end (632) as shown in FIG.13. In other areas, first bead of adhesive (648) is spaced apart fromsecond bead of adhesive (650) along at least a portion of a length ofbuttress (622). Second bead of adhesive (650) extends further proximallycompared to first bead of adhesive (648). Furthermore, first and secondbeads of adhesive (648, 650) extend distally to substantially the sameextent relative to buttress (622). In the present example, while firstand second beads of adhesive (648, 650) have different shapes orpatterns, both extend continuously from proximal end (630) to distal end(632) of buttress (622).

Now considering adhesive (620) as applied to second edge region (636),adhesive (620) comprises a third bead (652) and a fourth bead (654).Each bead of adhesive (652, 654) extends generally from proximal end(630) of buttress (622) to distal end (632) of buttress (622). Thirdbead of adhesive (652) partially overlaps fourth bead of adhesive (654)along at least a portion of a length of buttress (622), specifically inthe present example near distal end (632) and near proximal end (630).In other areas, third bead of adhesive (652) is spaced apart from fourthbead of adhesive (654) along at least a portion of a length of buttress(622). Fourth bead of adhesive (654) extends further proximally comparedto third bead of adhesive (652). Furthermore, third and fourth beads ofadhesive (652, 654) extend distally to substantially the same extentrelative to buttress (622). Third bead of adhesive (652) isdiscontinuous near a middle section of buttress (622), where there is aspace or gap (660) in third bead of adhesive (652). In contrast, fourthbead of adhesive (654) extends continuously from proximal end (630) todistal end (632) of buttress (622).

As mentioned above, first and second beads of adhesive (648, 650) arecollectively asymmetrical with third and fourth beads of adhesive (652,654) about longitudinal axis (A4) and lateral axis (A5). As alsomentioned above, buttress (622) is configured to be cut into two halvesabout a longitudinal centerline of buttress (622). A first half of cutbuttress (622) would include first edge region (634) and about half ofcenter region (638), while a second half of cut buttress (622) wouldinclude second edge region (636) and about the other half of centerregion (638).

Considering now adhesive (620) as applied at proximal and distal ends(630, 632) of respective halves of buttress (622), in the presentexample, an uneven distribution of adhesive (620) is used. With respectto the first half of a cut buttress (622), there is more adhesive (620)at a middle region of buttress (622) than at proximal and distal ends(630, 632) of buttress (622). However, with respect to the second halfof a cut buttress (622), there is more adhesive (620) at proximal anddistal ends (630, 632) of buttress (522) than at the middle region ofbuttress (622). Referring to FIG. 13, these differences in adhesive(620) amounts are shown by circled regions, where first regions (R1)have more adhesive (620) than second regions (R2).

When using two buttress assemblies (616), when applied to end effector(40), each buttress assembly (616) is oriented opposite the other withfirst surfaces (626) containing adhesive (620) facing away from eachother. In this arrangement, first edge region (634) of buttress assembly(616) attached with anvil (60) will be above and aligned with secondedge region (636) of buttress assembly (616) attached with staplecartridge (70). Similarly, second edge region (636) of buttress assembly(616) attached with anvil (60) will be above and aligned with first edgeregion (634) of buttress assembly (616) attached with staple cartridge(70). In this arrangement, first regions (R1) having more adhesive (620)will be oriented opposite and aligned with second regions (R2) havingless adhesive (620). By way of example only, at proximal end (630),buttress assembly (616) attached with anvil (60) will have first region(R1) positioned opposite and aligned with second region (R2) of theother buttress assembly (616) that is attached with staple cartridge(70). Likewise, and still at proximal end (630), buttress assembly (616)attached with anvil (60) will have second region (R2) positionedopposite and aligned with first region (R1) of the other buttressassembly (616) that is attached with staple cartridge (70). At distalend (632), buttress assembly (616) attached with anvil (60) will havesecond region (R2) positioned opposite and aligned with first region(R1) of the other buttress assembly (616) that is attached with staplecartridge (70). Likewise, and still at distal end (632), buttressassembly (616) attached with anvil (60) will have first region (R1)positioned opposite and aligned with second region (R2) of the otherbuttress assembly (616) that is attached with staple cartridge (70).Near the middle region, buttress assembly (616) attached with anvil (60)will have first region (R1) positioned opposite and aligned with secondregion (R2) of the other buttress assembly (616) that is attached withstaple cartridge (70). Likewise, and still at the middle region,buttress assembly (616) attached with anvil (60) will have second region(R2) positioned opposite and aligned with first region (R1) of the otherbuttress assembly (616) that is attached with staple cartridge (70).

When considering buttress assembly (616) before it is cut in halves,there are three first regions (R1) in the present example for buttressassembly (616) attached on anvil (60) side of end effector (40). Onesuch first region (R1) is within first edge region (634) at the middleregion of buttress (622), another first region (R1) is within secondedge region (636) at distal end (632), and another first region (R1) isalso within second edge region (636) at proximal end (630). This is thesame with respect to buttress assembly (616) attached on staplecartridge (70) side of end effector (40). These first regions (R1) withthe more adhesive help buttresses (622) stay attached and aligned to andwith the respective parts of end effector (40) when aggressivelymanipulating end effector (40), i.e. when piercing through ostomies,sliding axially onto tissue, etc. Furthermore, because buttressassemblies (616) are not yet cut, these areas of greater adhesive workto attach and retain the entire buttress assembly (616) with itsrespective parts of end effector (40).

Still considering buttress assembly (616) before it is cut in halves,there are three second regions (R2) in the present example for buttressassembly (616) attached on anvil (60) side of end effector (40). Onesuch second region (R2) is within first edge region (634) at proximalend (630), another is within first edge region (634) at distal end(632), another is within second edge region (636) at the middle regionof buttress (622). This is the same with respect to buttress assembly(616) attached on staple cartridge (70) side of end effector (40). Thesesecond regions (R2) with the less adhesive help buttresses (622)properly release from end effector (40) after a cut and stapleoperation. However, because buttress assemblies (616) are not yet cut,these areas of lower adhesive are still attached and retained on theirrespective parts of end effector (40) in part due to those first regions(R1) with greater adhesive (620) as discussed above.

Referring to FIG. 14, a side view of end effector (40) is shown duringan exemplary opening operation after a cut and staple action, and thusafter buttress assembly (616) has been cut into halves. With theasymmetric distribution of adhesive (620) described above, when endeffector (40) is opened after cutting and stapling, having first regions(R1) with more adhesive (620) opposite second regions (R2) with lessadhesive (620) reduces the adhesive attachment to the respectivesurfaces on anvil (60) and staple cartridge (70). For instance, uponopening end effector (40) after a cutting and stapling action, secondregions (R2) with less adhesive (620) detach or release from endeffector (40) prior to first regions (R1) with the greater adhesive(620). As mentioned above, prior to cutting buttress assembly (616) intohalves, buttress assembly (616) operates as a unit and thus the combinedfirst areas (R1) with greater adhesive provide for attachment andretention of buttress assembly (616). However, this changes oncebuttress assembly (616) is cut into halves as second regions (R2) willnow release from end effector (40).

For ease of illustration, FIG. 14 shows end effector (40) loaded with asingle buttress assembly (616) on staple cartridge (70) side, where acut and staple operation has occurred such that the knife of endeffector (40) has cut buttress assembly (616) into halves. In FIG. 14,first half (662) and second half (664) of buttress assembly (616) areshown with their attachment and release profiles. First half (662)represents first edge region (634) and half of center region (638) asillustrated in FIG. 13. As shown, first half (662) has first region (R1)with the greater adhesive (620) located at a middle region of staplecartridge (70). Thus when opening end effector (40) initially, firsthalf (662) remains attached with staple cartridge (70) near the middleregion of staple cartridge (70). First half (662) has second region (R2)with less adhesive (620) located at the proximal and distal ends ofstaple cartridge (70). Thus when opening end effector (40) initially,first half (662) releases from staple cartridge (70) near the proximaland distal ends of staple cartridge (70).

Second half (664) represents second edge region (636) and half of centerregion (638) as illustrated in FIG. 13. As shown, second half (664) hasfirst region (R1) with the greater adhesive (620) located at theproximal and distal ends of staple cartridge (70). Thus when opening endeffector (40) initially, second half (664) remains attached with staplecartridge (70) near the proximal and distal ends of staple cartridge(70). Second half (664) has second region (R2) with less adhesive (620)located at the middle region of staple cartridge (70). Thus when openingend effector (40) initially, second half (664) releases from staplecartridge (70) near the middle region of staple cartridge (70). Thispattern of attachment and release post cutting and stapling would alsobe evident on anvil (60) side of end effector (40) for buttress assembly(616) loaded onto anvil (60).

Other than the disparity in adhesive (620) described above, anotherfactor that contributes to the release of buttress assembly (616) fromend effector (40) is the large aperture or large motion of distal end(41) of end effector (40) when being opened after a cut and stapleaction. This large range of motion for distal end (41) of end effector(40) also works with the fact that after the cut and staple action twoopposing halves of two buttress assemblies (616) are now stapledtogether with tissue therebetween. Accordingly, these factors providefor release of buttress assemblies (616) even at first regions (R1) thathave greater adhesive that was adhering buttress assemblies (616) torespective parts of end effector (40).

As shown and described in the examples above, using an asymmetricdistribution of adhesive (520, 620) on buttress assemblies (516, 616)allows for a reduction in the release force, or force required torelease buttress assemblies (516, 616) from end effector (40) afterbuttress assemblies (516, 616) are cut into halves. This allows forbuttress assemblies (516, 616) to be configured with a controlledrelease where certain portions of buttress assemblies (516, 616) areconfigured to release earlier or sooner than other portions.Furthermore, strategically locating regions of asymmetric adhesivedistribution provides for adequate attachment and retention of the uncutbuttress assemblies (516, 616). While multiple adhesive distributionshave been shown and described herein, other adhesive distributions canbe used to achieve desired attachment, retention, and release propertiesfor buttress assemblies described herein. In view of the teachingsherein, such other patterns of adhesive distribution for buttressassemblies described herein will be apparent to those of ordinary skillin the art.

IV. Exemplary Buttress Construction and Arrangement

FIGS. 15 and 16 illustrate buttress (322) of buttress assemblies (316,318). Buttress (322) comprises a multi-layer material that is laminatedtogether. In the present example, buttress (322) comprises a mesh layer(6326) and two film layers (6332, 6334). Mesh layer (6326) comprises aknitted synthetic absorbable material. In some examples, mesh layer(6326) is knit using yarns (6328) comprised of polyglactin 910, which is90% glycolide and 10% L-lactide. An example of polyglactin 910 ismanufactured by Ethicon Inc. under the brand name Vicryl®. In view ofthe teachings herein, other absorbable synthetic materials for use withmesh layer (6326) will be apparent to those of ordinary skill in theart.

FIG. 16 illustrates an enlarged portion of mesh layer (6326), showing anexemplary knit pattern produced by the arrangement of yarns (6328). Inthe present example, each yarn (6328) comprises a bundle or structurehaving 28 individual filaments. However, in other versions each yarn(6328) can comprise a single filament or a multifilament bundle withgreater or fewer than 28 individual filaments. An example of themultifilament structures of mesh layer (6326) can be seen in FIG. 18,where the uncut yarns in cross section illustrate multiple filaments(6329) that make up the multifilament structure of yarns (6328).

As best seen in FIG. 16, mesh layer (6326) comprises a plurality ofopenings (6330) defined by the knit yarns (6328). With its openings(6330) mesh layer (6326) comprises a porosity. Depending on the numberand/or size of openings (6330) the porosity of mesh layer (6326) can bechanged with various mesh layers (6326). Furthermore, the knit patternas well as the yarn size can influence openings (6330) and the resultantporosity. In the present example, plurality of openings (6330) areconfigured in size and/or number such that they promote tissue ingrowthwhen one side of mesh layer (6326) of buttress (322) is placed adjacentor in contact with tissue at a stapled site. In this manner, buttress(322) comprises one or more tissue ingrowth features, which areconfigured to promote tissue ingrowth with buttress (322). Such tissueingrowth can provide strength to the cut and stapled site and promotehealing of the tissue. In view of the teachings herein, various ways tomodify mesh layer (6328) to achieve a desired porosity, and/or size ofopenings (6330), and/or number of openings (6330), will be apparent tothose of ordinary skill in the art in view of the teachings herein.

Referring now to FIG. 18, as mentioned above, buttress (322) alsocomprises a film layer (6332). Film layer (6332) is configured as anadhesive layer. In the present example, film layer (6332) is located onone side of mesh layer (6326), and is configured to adhesively attachmesh layer (6326) with film layer (6334). Film layer (6332), in thepresent example, comprises a polydioxanone (PDO) film; however, in otherversions other types of film may be used and will be apparent to thoseof ordinary skill in the art in view of the teachings herein.Furthermore, film layer (6332) is about 8 micrometers in thickness inthe present example; however, in other versions the thickness of filmlayer (6332) may be greater or less than 8 micrometers. In someversions, the polydioxanone film can be included in the construct as athin film either on its own at the time of lamination or coextruded ontofilm layer (6334) prior to lamination to the mesh layer (6326).

Referring still to FIG. 18, and also FIG. 17, film layer (6332) is alsoin contact with film layer (6334). Film layer (6334) contacts film layer(6332) on the side opposite to where film layer (6332) contacts meshlayer (6326). In the present example, film layer (6334) is configured asan adhesion barrier to prevent tissue adhesions from forming at or nearthe surgically stapled site. Film layer (6334), in the present example,is constructed of poliglecaprone 25. An example poliglecaprone 25 ismanufactured by Ethicon Inc. under the brand name Moncryl®. In otherversions, other types of film may be used and will be apparent to thoseof ordinary skill in the art in view of the teachings herein. In thepresent example, film layer (6334) is about 10 micrometers in thickness;however, in other versions the thickness of film layer (6334) may begreater or less than 10 micrometers.

Film layer (6334) is also substantially continuous in the presentexample, and is configured to receive adhesive (320) as described aboveand as shown best in FIG. 17. With this configuration, film layer (6334)is on the side of buttress (322) that releasably attaches with endeffector (40) when buttress assemblies (316, 318) are loaded to endeffector (40) as described above. Furthermore, with this configuration,after actuating end effector (40) in a stapling action, film layer(6334) is positioned facing away form the stapled tissue site, whereasopenings (6330) of mesh layer (6326) are positioned facing the stapledtissue site as mentioned above to promote tissue ingrowth. While filmlayer (6334) is illustrated as substantially continuous, with theexception of slits (6336) described further below, in some otherversions film layer (6334) can include openings therein, for example asdisclosed in U.S. Pat. No. 8,579,990, entitled “Tissue Repair Devices ofRapid Therapeutic Absorbency,” issued Nov. 12, 2013, and incorporated byreference herein.

When constructing buttress (322), mesh layer (6326) and film layers(6332, 6334) are laminated together to form the multi-layer materialcomprising buttress (322). In one version, the lamination occurs underelevated pressure and temperature. Buttress (322) is subjected to theseconditions for a predetermined time to achieve acceptable lamination ofthe layers.

In the present example, buttress (322) is mechanically cut from a largerpiece or fabric of multi-layer material having the same construction asdescribed above for buttress (322). This mechanical cutting can be doneat lower temperatures compared to other cutting applications, whichallows for buttresses (322) to be cut from larger fabrics while avoidingcharred or burnt edges that can occur with heated cutting techniques.

Also in the present example, buttresses (322) are mechanically cut outfrom the larger fabric such that the knit pattern is cut along a 45degree angle relative to a longitudinal axis (LA) of buttress (322).Referring to FIGS. 15 and 16, the knit pattern of mesh layer (6326) isillustrated having been cut out at about 45 degrees relative tolongitudinal axis (LA). For instance, axis (A1) illustrates thedirection of the knit pattern of mesh layer (6326). Furthermore, theintersection of axis (A1) and longitudinal axis (LA) of buttress (322)forms an angle (a), which is approximately 45 degrees in the presentexample. By using this configuration for the cut out angle, unravelingof the mesh layer (6326) of cut out buttress (322) can be avoided. Inview of the teachings herein, other cut out angles and ways to preventunraveling of a cut mesh layer (6326) will be apparent to those ofordinary skill in the art.

Referring again to FIGS. 15 and 17, buttress (322) also comprisesmultiple slits (6336) that extend longitudinally along buttress (322).Slits (6336) extend all the way through mesh layer (6326), through filmlayer (6332), and through film layer (6334). Furthermore, slits (6336)are positioned to generally divide buttress (6332) into two equalsections. Referring to FIG. 4, when buttress assemblies (316, 318) areused with end effector (40) in a cutting and stapling procedure, theknife (not shown) of the stapler will travel longitudinally down endeffector (40) to cut clamped tissue and at the same time cut buttresses(322) of buttress assemblies (316, 318) along slits (6336). This createsthe cut and stapled site as illustrated in FIG. 4. Slits (6336) act asprecuts in buttress (6332) such that during a cutting and staplingaction, buttress (6332) offers less resistance to being cut, whichpromotes buttress (6332) remaining properly placed relative to thesurgically cut and stapled site, instead of buttress (6332) being pushedlongitudinally by the cutting knife and bunching. While the presentexample uses slits (6336) to precut and promote ease of cutting buttress(322), in view of the teachings herein, other techniques and precutgeometries can be used and will be apparent to those of ordinary skillin the art.

V. Exemplary Packaging Assembly for Buttress Applicator

As mentioned above, it can be beneficial to apply a buttress to a cutand stapled surgical site as a reinforcement. In doing so, the buttressmust be loaded onto an end effector of a surgical stapler, and thenapplied at the site releasing from the end effector in the process. Inuse the buttress can be configured to be bioabsorbable so over time itis completely absorbed by the body of the patient. To achieve thedesired loading and release properties of the buttress, as well asdesired reinforcement properties when in use, the buttress materialitself, as well as materials applied to the buttress such as adhesive,can be susceptible to degradation when exposed prematurely toenvironmental factors such as moisture, etc. Using a packaging assemblyas shown and described herein can preserve the integrity of the buttressprior to its use and application.

A. Exemplary Outer Tray and Foil Assembly

FIGS. 19-24 illustrate an exemplary packaging assembly (8010) for abuttress applicator of a surgical stapler. Packaging assembly comprisesa foil assembly or foil pouch (8400) and an outer tray (8500). Foilpouch (8400) comprises a top layer (8402) as shown in FIG. 19, and abottom layer (8404) as shown in FIGS. 23-24. Outer tray (8500) ispositioned such that foil pouch (8400) sits within outer tray (8500). Inthis respect, outer tray (8500) comprises a cavity or space (8502), asshown in FIG. 26, configured to received foil pouch (8400). At least aportion of outer tray (8500) has a shape that matches or closely matchesa shape of an underside (8406) of foil pouch (8400) as best seen inFIGS. 23 and 24. In this manner in the present example, a surface (8504)of cavity (8502) is immediately adjacent to underside (8406) of foilpouch (8400). With this configuration, outer tray (8500) is configuredto protect bottom layer (8404) of foil pouch (8400) from damage byfitting closely against bottom layer (8404).

Referring to FIG. 20, outer tray (8500) is configured for stacking withouter tray (8500) comprising a smooth flat underside (8506). The smoothand flat nature of underside (8506) allows for stacking multiplepackaging assemblies (8010) on top of one another, without undersidesurface (8506) damaging top layer (8402) of an adjacent foil pouch(8400). The size and shape of underside (8506) is configured such that aflap (8602) of an inner tray (8600)—as shown in FIGS. 23 and 24—of onepackaging assembly (8010) can provide structural support to bear theweight of another packaging assembly (8010) stacked thereupon. In thismanner, top layer (8402) of foil pouch (8400) is not required in allcases to bear the weight or load of whatever packaging assemblies (8010)are stacked above, which preserves the integrity of foil pouch (8400) bypreventing creasing or puncture of top layers (8402) of stackedpackaging assemblies (8010).

Still referring to FIG. 20, outer tray (8500) also comprises recess(8508) on a bottom side. Recess (8508) is configured as an area that canbe easily accessed and grasped by a user to pick up a select packagingassembly (8010) either separately or from a group of stacked packagingassemblies (8010). With this configuration, opposite recess (8508) on atop side of outer tray (8500) is a flat surface (8510) as shown in FIG.26, which is configured as a complementary area that can be easilyaccessed and grasped by a user to pick up a select packaging assembly(8010) either separately or from a group of stacked packaging assemblies(8010). In this manner, outer tray (8500) is configured with anaccessible area for a user to grasp, hold, or pick up packaging assembly(8010) easily and safely without risk of contacting buttress and/orbuttress applicator.

B. Exemplary Foil Assembly and Inner Tray

FIG. 25 illustrates a portion of packaging assembly (8010), where outertray (8500) has been set aside. Furthermore, foil pouch (8400) is shownas partially opened, with top layer (8402) peeled back and away frombottom layer (8404). As shown, foil pouch (8400) comprises an interior(8408) between top and bottom layers (8402, 8404). Furthermore, interior(8408) is configured to receive, retain, or hold inner tray (8600),which receives, retains, or holds a buttress applicator (300). Prior totop layer (8402) and bottom layer (8404) being separated, top layer(8402) and bottom layer (8404) are connectable to seal inner tray (8600)with buttress applicator (300) within foil pouch (8400). In the presentexample, top and bottom layers (8402, 8404) seal together to form ahermetic seal. In this way, the seal is airtight such that moistureoutside foil pouch (8400) cannot enter and thereby damage or degrade thebuttress assemblies (316, 318) of buttress applicator (300). As notedand shown, the hermetic seal between top layer (8402) and bottom layer(8404) is selective and not permanent such that a user can separate topand bottom layers (8402, 8404) to retrieve buttress applicator (300). Insome examples, foil pouch (8400) is sealed under dry nitrogen to provideinterior (8408) with an extremely low moisture and oxygen environment.

With foil pouch (8400) sealed and surrounding inner tray (8600), toplayer (8402) of foil pouch (8400) and bottom layer (8404) of foil pouch(8400) are configured to closely follow the contour of inner tray(8600). This close fit, which can be seen in the cross-section views ofFIGS. 23 and 24, promotes protection of foil pouch (8400) from damagewhen and if being contacted, as inner tray (8600) provides support totop and bottom layers (8402, 8404) of foil pouch (8600) from the insideof foil pouch (8400) outward. By way of example only, if too much spaceis provided between foil pouch (8400) and inner tray (8600) when innertray (8600) is sealed within foil pouch (8400), then top and/or bottomlayers (8402, 8404) of foil pouch (8400) are more susceptible to damagein the form of creases, cuts, and/or punctures.

With the configuration described above, packaging assembly (8010) isconfigured with two trays: inner tray (8600) and outer tray (8500).Moreover, inner tray (8600) and outer tray (8500) are separable from oneanother. In the present example, foil pouch (8400) separates inner tray(8600) from outer tray (8500), and more specifically, bottom layer(8404) of foil pouch (8400) separates inner tray (8600) from outer tray(8500). Foil pouch (8400) is configured as an impermeable material suchthat water and air cannot pass through layers (8402, 8404) of foil pouch(8400). Thus, in one version packaging assembly (8010) comprises outertray (8500) and inner tray (8600) configured to selectively retainbuttress applicator (300), where there is an impermeable materialpositionable between outer tray (8500) and inner tray (8600).Furthermore, the impermeable material surrounds buttress applicator(300) retained by inner tray (8600) forming a hermetic seal around innertray (8600) and buttress applicator (300). Further yet, with theabove-described configuration, outer tray (8500) is configured toprotect the impermeable material from damage. While the present exampleshows packaging assembly (8010) with two trays (8600, 8500) separable byimpermeable bottom foil layer (8404), in other versions, packagingassembly (8010) can be configured with greater or fewer trays andseparable by other materials as will be appreciated by those of ordinaryskill in the art in view of the teachings herein.

While examples of packaging assembly (8010) herein describe pouch (8400)as foil pouch (8400), it should be understood that pouch (8400) is notlimited to being constructed of foil. In other examples, pouch (8400) isconstructed of other suitable materials that can provide a hermeticseal. Such other suitable materials can include impermeable films suchas films made of various plastics. In view of the teachings herein,other materials for use in constructing pouch (8400) of packagingassembly (8010) will be apparent to those of ordinary skill in the art.

C. Exemplary Inner Tray and Buttress Applicator

FIGS. 27-29 illustrate inner tray (8600), including buttress applicator(300). In some instances buttress applicator (300) is referred to hereinas merely applicator (300). It should be understood that these terms areused and understood herein to be interchangeable. As illustrated, innertray (8600) comprises a base (8606), flap (8602), and a living hinge(8608) connecting flap (8602) with base (8606). Base (8606) of innertray (8600) is configured to selectively retain applicator (300). Flap(8602) is rotatable from a closed position as seen in FIGS. 25-27, to anopen position as seen in FIGS. 28 and 29. In the closed position, flap(8602) at least partially covers applicator (300) when applicator (300)is retained within base (8606). In the open position, flap (8602)reveals applicator (300) such that it may be removed from inner tray(8600).

Inner tray (8600) includes fastening features (8609) that are configuredto selectively engage so that flap (8602) connects with base (8606) asmentioned above. In the present example, one fastening feature (8609)comprises fastening members (8610, 8612), with one fastening member(8610) located on an underside (8614) of flap (8602), and the otherfastening member (8612) located on a ridge (8618) within base (8606).Fastening members (8610) engage with fastening members (8612) when flap(8602) is in the closed position. While the illustrated version of FIGS.27-29 shows a pair of fastening features (8609), in other versionsgreater or fewer fastening features (8609)—and their associatedfastening members (8610, 8612)—may be used to achieve selective closureof flap (8602) with body (8606). By way of example only, and notlimitation, FIGS. 31 and 32 illustrate another exemplary inner tray(8700). Inner tray (8700) is the same as inner tray (8600) with theexception that inner tray (8700) comprises two pair, or four total,fastening features (8709), each with fastening members (8710) that areconfigured to selectively engage with fastening members (8712).

Returning to FIGS. 27 and 28, in some versions, inner tray (8600) isconfigured such that applicator (300) only sits within base (8606) andwith flap (8602) closable when applicator (300) is oriented orpositioned in a certain manner. For instance, as shown in FIG. 27, innertray (8600) presents a distal end (8360) of applicator (300) for a userto grasp. Proximal end (8362) of applicator (300) is covered by flap(8602) when flap (8602) is closed. Flap (8602) is configured with guidefeatures (8616) along its underside (8614), where guide features (8616)are configured to locate within a space created by an open end (8301) ofapplicator (300). Because applicator (300) is a closed structure alongits distal end (8360), if applicator (300) is positioned within base(8606) with its proximal end (8362) presenting towards a user forgrasping—opposite of what is shown in FIG. 27—then guide features (8616)will interfere with the closed distal end (8360) of applicator (300)such that flap (8602) cannot close fully with fastening members (8610)engaging fastening members (8612).

In this configuration, a poka-yoke relationship or configuration existsamong inner tray (8600) and applicator (300) to ensure applicator (300)is oriented with its distal end (8360) visible and its proximal end(8362) covered by flap (8602) when flap (8602) is closed. Thisorientation of applicator (300) relative to inner tray (8600) providesthat flap (8602) shields buttress assemblies (316, 318) of applicator(300) so that buttress assemblies (316, 318) are inaccessible. In thismanner, flap (8602) protects buttress assemblies (316, 318) from contactwhen applicator (300) is positioned within inner tray (8600) with flap(8602) closed. Additionally, base (8606) of inner tray (8600) furtherincludes ridges (8618) and stops (8628, 8630) as shown in FIGS. 28 and29 that help minimize applicator (300) shifting or moving when seatedwithin base (8606) of tray (8600). For instance, ridges (8618) helpminimize lateral movement of applicator (300), while stops (8628, 8630)help minimize longitudinal movement of applicator (300).

Referring to FIG. 27, inner tray (8600) and applicator (300) areconfigured in the present example such that flap (8602) can bedisengaged from base (8606) by lifting distal end (8360) of applicator(300). In this way, housing portion (302) of applicator (300) pushes onunderside (8614) of flap (8602) to release the engagement betweenfastening members (8610, 8612). This opening technique helps prevent orshield buttress assemblies (316, 318) from contact. Still other ways toopen flap (8602) exist. For example, flap (8602) comprises peninsulaportion (8620). Portion (8620) may be grasped by a user and lifted toopen flap (8602) for removal of applicator (300). Peninsula portion(8620) further allows for a center region of applicator (300) havingbuttress assemblies (316, 318) to be covered when flap (8602) is closed,while exposing distal end (8360) of applicator (300) for visualizationor grasping by a user. Still further, flap (8602) presents a leadingedge (8622), which can be contacted by a user and lifted to move flap(8602) from its closed position to its open position. In view of theteachings herein, other ways to facilitate opening flap (8602) to removeapplicator (300) from inner tray (8600) while protecting buttressassemblies (316, 318) from contact and other environmental exposure willbe apparent to those of ordinary skill in the art.

D. Exemplary Inner Tray and Desiccant Material

As shown in FIGS. 27 and 30, inner tray (8600) is configured toselectively retain a desiccant material (8604). Desiccant material(8604) is configured to preferentially absorb any moisture withininterior (8408) of foil pouch (8400). In this way, desiccant material(8604) may be an overdried material that is combined with inner tray(8600) and then sealed within foil pouch (8400). Any moisture thatexists within foil pouch (8400) will be first absorbed by the overdrieddesiccant material (8604) before being absorbed by buttress assemblies(316, 318) of buttress applicator (300). In the present example,desiccant material (8604) comprises a piece of paperboard, but in otherversions desiccant material (8604) can be made of other materials suchas cotton, silica, and other materials that will be apparent to those ofordinary skill in the art in view of the teachings herein.

Referring to FIG. 30, inner tray (8600) comprises an area (8624) on anouter surface (8626) of flap (8602) that is configured to selectivelyretain desiccant material (8604). In this configuration, inner tray(8600) selective retains desiccant material (8604) in a way wheredesiccant material (8604) does not contact applicator (300). In oneexample, area (8624) of flap (8602) comprises tabs. In the presentexample, inner tray (8600) comprises a molded plastic and accordinglyarea (8624) and tabs are molded features of inner tray (8600). Desiccantmaterial (8604) and tabs are configured such that desiccant material(8604) can be slid along area (8624) with tabs sliding above desiccantmaterial (8604) to selectively retain desiccant material (8604) adjacentto area (8624) of flap (8602). Similarly, desiccant material (8604) canbe removed from inner tray (8600) by sliding desiccant material (8604)distally away from area (8624) such that tabs no longer impinge on andretain desiccant material (8604) with inner tray (8600). Referring toFIG. 30, in another example, area (8624) of flap (8602) comprisesopenings (8632). In the present example, inner tray (8600) comprises amolded plastic and accordingly area (8624) and openings (8632) aremolded features of inner tray (8600). Furthermore, desiccant material(8604) comprises tabs (8633), which are engagement features that can beinserted into and received by openings (8632) such that desiccantmaterial (8604) can be selectively attached with area (8624). In thepresent example, tabs (8633) are resiliently biased outward from alongitudinal centerline of desiccant material (8604). When insertedwithin openings (8632) tabs (8633) deflect inward and the resilient biasof tabs (8633) provide a selective interference fitting between tabs(8633) and openings (8632) to selectively retain desiccant material(8604) with area (8624) of flap (8602). Desiccant material (8604) can beremoved from inner tray (8600) by pulling desiccant material (8604)upward away from area (8624) of flap (8602) to overcome the interferencefitting such that tabs (8633) disengage from openings (8632). In view ofthe teachings herein, other ways to attach and remove desiccant material(8604) with inner tray (8600) will be apparent to those of ordinaryskill in the art.

VI. Exemplary Method of Packaging a Buttress Applicator

FIG. 33 schematically illustrates an exemplary method for packaging abuttress applicator (8800) such as buttress applicators (200, 300)described above. At step (8802), applicator (300) with buttressassemblies (316, 318) is obtained, along with inner tray (8600),desiccant material (8604), foil assembly (8400), and outer tray (8500).At step (8804), applicator (300) is positioned within inner tray (8600).In some instances this includes positioning applicator (300) is aspecific orientation relative to base (8606) of inner tray (8600) sothat applicator (300) sits flat within base (8606) of inner tray (8600)and allows flap (8602) to properly and fully close. At step (8806), flap(8602) is secured in the closed position by engaging fastening features(8609). At step (8808), desiccant material (8604) is attached with area(8624) of inner tray (8600) and selectively secured by tabs (8632). Atstep (8810), inner tray (8600) is positioned within foil assembly(8400). In particular, inner tray (8600) may be placed between top andbottom layers (8402, 8404) of foil assembly (8400). At step (8812), foilassembly (8400) is sealed to hermetically seal inner tray (8600) andapplicator (300) within foil assembly (8400). At step (8814) sealed foilassembly (8400) containing inner tray (8600) with applicator (300) ispositioned within outer tray (8500), where outer tray (8500) isconfigured to protect foil assembly (8400) from damage.

While the above steps describe one exemplary packaging method, othermethods may be used, or modifications to method (8800) may be made aswill be apparent to those of ordinary skill in the art in view of theteachings herein. For instance, the order of the steps of method (8800)as shown and described above are not required in all versions. Forinstance, where practical or convenient or desired, certain steps can becompleted before others such that the above shown and described stepsshould not be considered limited to their presented sequential order.Still other modifications may involve adding or omitting certain steps.

VII. Exemplary Buttress Assembly for a Buttress Applier Cartridge

In some instances, it may be desirable to use an exemplary buttressapplier cartridge assembly (5010) as shown in FIG. 34 to equip asurgical instrument with a buttress assembly (5012) for forming staplesin tissue with a buttress (5014). Such buttress (5014) inhibits theformed staples from pulling through the tissue to thereby reduce a riskof tissue tearing at or near the site of formed staples. In addition toor as an alternative to providing structural support and integrity to aline of staples, buttress (5014) may provide various other kinds ofeffects such as spacing or gap-filling, administration of therapeuticagents, and/or other effects. Prior to use with the surgical instrument,one or more buttresses (5014) is releasably retained on a buttressapplier cartridge (5016), which is configured to deposit buttressassembly (5010) onto surgical instrument for use as discussed below inmore detail in an exemplary surgical instrument (5018) (see FIG. 43A).

Additional features may be combined as applicable with the followingexample of buttress applier cartridge assembly (5010). Such features aredescribed in U.S. Pat. App. No. [ATTORNEY DOCKET NO.END8634USNP.0663974], entitled “Adhesive Distribution on Buttress forSurgical Stapler,” filed on even date herewith; U.S. Pat. App. No.[ATTORNEY DOCKET NO. END8636USNP.0663978], entitled “Surgical StaplerButtress with Tissue In-Growth Promotion,” filed on even date herewith;U.S. Pat. App. No. [ATTORNEY DOCKET NO. END8637USNP.0663981], entitled“Applicator for Surgical Stapler Buttress,” filed on even date herewith;U.S. Pat. App. No. [ATTORNEY DOCKET NO. END8638USNP.0663983], entitled“Packaging for Surgical Stapler Buttress,” filed on even date herewith;U.S. Pat. App. No. [ATTORNEY DOCKET NO. END9071USNP1.0714576], entitled“Method of Applying Buttresses to Surgically Cut and Stapled Sites,”filed on even date herewith; U.S. Pat. App. No. [ATTORNEY DOCKET NO.END9072USNP1.0714574], entitled “Curved Tip Surgical Stapler ButtressAssembly Applicator with Opening Feature for Curved Tip Alignment,”filed on even date herewith; U.S. Pat. App. No. [ATTORNEY DOCKET NO.END9073USNP1.0714572], entitled “Curved Tip Surgical Stapler ButtressAssembly Applicator with Proximal Alignment Features,” filed on evendate herewith; and U.S. Pat. App. No. [ATTORNEY DOCKET NO.END9075USNP1.0714570], entitled “Curved Tip Surgical Stapler ButtressAssembly Applicator with Compression Layer Pocket Feature,” filed oneven date herewith, the disclosures of which are hereby incorporated byreference.

A. Exemplary Buttress Applier Cartridge

FIGS. 34-35 show buttress applier cartridge assembly (5010) including apair of buttress assemblies (5012) releasably retained on buttressapplier cartridge (5016), which supports and protects buttressassemblies (5012) prior to use and further aids with loading buttressassemblies (5012) on surgical instrument (5110) (see FIG. 43A). Buttressapplier cartridge (5016) of the present example includes an open end(5018) and a closed end (5020). Open end (5018) is configured to receiveend effector (5112) (see FIG. 43A) as described below in greater detail.Buttress applier cartridge (5016) further includes a housing assembly(5024) having an upper housing (5026) and a lower housing (5028), whicheach generally define a “U” shape to present open end (5018). Variouscomponents are interposed between upper and lower housings (5026, 5028).In particular, these components include a platform (5030), a pair ofactuator sleds (5032) having arms (5034), and a chassis (5036).

Platform (5030) of the present example supports upper buttress assembly(5012) on one side of platform (5030) and lower buttress assembly (5012)on the other side of platform (5030). Platform (5030) is exposed inrecesses that are formed between the prongs of the “U” configuration ofupper and lower housings (5026, 5028). Thus, upper housing (5026) has anupper gap (5037) extending to the open end (5018) along an upper surfaceof platform (5030), and lower housing (5028) similarly has a lower gap(5038) extending to the open end (5018) along the lower surface ofplatform (5030). The location of platform (5030) and buttress assemblies(5012) in such recesses may prevent inadvertent contact between buttressassemblies (5012) and other devices in the operating room. In otherwords, upper and lower housings (5026, 5028) may provide some degree ofphysical shielding of buttress assemblies (5012).

In the present example, the outer edges of platform (5030) are capturedbetween upper and lower housings (5026, 5028) and include retentionfeatures (not shown) that further engage upper and lower housings (5026,5028) to prevent platform (5030) from sliding relative to upper andlower housings (5026, 5028). In some versions, platform (5030) is formedof a material that provides a high coefficient of friction, therebyreducing any tendency that buttress assemblies (5012) might otherwisehave to slide along corresponding surfaces of platform (5030). Forinstance, platform (5030) may comprise an elastomeric material and/or afoam material. In some instances, platform (5030) is formed of acompressible foam material that is configured to maintain a compressedconfiguration after being compressed by end effector (5112) (see FIG.43A). By way of example only, platform (5030) may comprise Santoprene,closed-cell polyurethane foam, any other compressible material, and/or amaterial that may be made compressible via geometry (e.g., a rubbermaterial with deformable standing features). Various suitable materialsand structural configurations that may be used to form platform (5030)will be apparent to those of ordinary skill in the art in view of theteachings herein.

Chassis (5036) is configured to cooperate with upper and lower housings(5026, 5028) to provide a mechanical ground for moving components ofbuttress applier cartridge (5016) and provide structural support forcomponents of buttress applier cartridge (5016). Chassis (5030) furtherincludes integral gripping features (5040) that are exposed on oppositesides of housing assembly (5024). Gripping features (5040) have asurface geometry configured to promote an operator's grip of buttressapplier cartridge (5016) during use of buttress applier cartridge(5016). Various suitable configurations that may be used for grippingfeatures (5040) will be apparent to those of ordinary skill in the artin view of the teachings herein. Similarly, various surface treatments(e.g., elastomeric material, etc.) that may be applied to grippingfeatures (5040) will be apparent to those of ordinary skill in the artin view of the teachings herein.

Actuator sleds (5032) are slidably positioned on opposite faces ofchassis (5030). Arms (5034) of actuator sleds (5032) extend laterallyinward to selectively and releasably secure buttress assemblies (5012)to platform (5030). In particular, FIG. 34 show arms (5034) positionedsuch that buttress assemblies (5012) are interposed between the freeends of arms (5034) and platform (5030). Arms (5034) are movablelaterally outwardly such that arms (5034) disengage buttress assemblies(5012) as shown in FIG. 35, thereby enabling buttress assemblies (5012)to be removed from platform (5030). In the present example, arms (5034)are configured to bear against buttress assemblies (5012), therebypinching buttress assemblies (5012) against platform (5030). Othersuitable ways in which arms (5034) may engage buttress assemblies (5012)will be apparent to those of ordinary skill in the art in view of theteachings herein.

B. Exemplary Buttress Assembly

FIG. 35 shows upper and lower buttress assemblies (5012) removed frombuttress applier cartridge (5016), whereas FIG. 36 and FIG. 37 showupper buttress assembly (5012) in more detail. Notably, in the presentexample, upper and lower buttress assemblies (5012) are structurallyidentical, but for the relative positions of upper and lower buttressassemblies (5012) retained on buttress applier cartridge (5016).Buttress applier cartridge assembly (5010) may thus be used in more thanone orientation with surgical instrument (5110) (see FIG. 43A). It willbe appreciated that the following description of upper buttress assembly(5012) similarly applies to lower buttress assembly (5012) but for therespective orientations.

With respect to FIG. 36 and FIG. 37, upper buttress assembly (5012)includes a buttress (5014) and an upper adhesive layer (5042). Buttress(5014) of the present example more particularly has a three-layer,polymer construction including a core layer (5044) sandwiched betweentwo outer layers (5046) to be collectively strong yet flexible tosupport a line of staples. In the present example, core layer (5044) isa polyglactin 910 material, which is manufactured and sold by Ethicon,Inc. of Somerville, N.J. as VICRYL, whereas each outer layer is apolydioxanone (PDO) film material. More particularly, the polyglactin910 material of core layer (5044) in one example has a transversethickness of 206 micrometers, while the polydioxanone (PDO) filmmaterial of each outer layer (5046) has a transverse thickness of 8micrometers. In another example, the polydioxanone (PDO) film materialof each outer layer (5046) has a transverse thickness of 9.5micrometers. Buttress (5014) of the present example is formed bylaminating core layer (5044) between outer layers (5046) under apredetermined pressure, a predetermined temperature, and a predeterminedtime. Once laminated in one example, the polyglactin 910 material ofcore layer (5044) has a transverse thickness of 161.5 micrometers. Suchmaterials of layers (5044, 5046) in one example are composed of fibersarranged to extend in a direction 45 degrees from a longitudinallyextending direction along each buttress assembly (5012) to controllateral material stretch. Buttress (5014) is further mechanically cut tosize thereby inhibiting abrasive edges, such as burrs and/ordelamination, that could damage sensitive tissues. It will beappreciated that alternative methods of cutting buttresses (5014), suchas a laser cutting or hot knife cutting, may be similarly used.

By way of further example only, each buttress (5014) may comprise one ormore portions of the following: NEOVEIL absorbable PGA felt by GunzeLimited, of Kyoto, Japan; SEAMGUARD polyglycolic acid: trimethylenecarbonate (PGA:TMC) reinforcement material by W.L. Gore & Associates,Inc., of Flagstaff, Ariz.; PERI-STRIPS DRY with VERITAS Collagen Matrix(PSDV) reinforcement material, by Baxter Healthcare Corporation ofDeerfield, Ill.; BIODESIGN biologic graft material by Cook Medical,Bloomington, Ind.; and/or SURGICEL NU-KNIT hemostat material by Ethicon,Inc. of Somerville, N.J. Still other suitable materials that may be usedto form each buttress (5014) will be apparent to those of ordinary skillin the art in view of the teachings herein.

In addition or in the alternative, each buttress (5014) may comprise amaterial including, for example, a hemostatic agent such as fibrin toassist in coagulating blood and reduce bleeding at the severed and/orstapled surgical site along tissue. As another merely illustrativeexample, each buttress (5014) may comprise other adjuncts or hemostaticagents such as thrombin may be used such that each buttress (5014) mayassist to coagulate blood and reduce the amount of bleeding at thesurgical site. Other adjuncts or reagents that may be incorporated intoeach buttress (5014) may further include but are not limited to medicalfluid or matrix components. Merely illustrative examples of materialsthat may be used to form each buttress (5014), as well as materials thatmay be otherwise incorporated into each buttress (5014), are disclosedin U.S. patent application Ser. No. 14/667,842, entitled “Method ofApplying a Buttress to a Surgical Stapler,” filed Mar. 25, 2015, thedisclosure of which is incorporated by reference herein. Alternatively,any other suitable materials may be used.

By way of further example only, each buttress (5014) may be constructedin accordance with at least some of the teachings of U.S. Patent Pub.No. 2012/0241493, entitled “Tissue Thickness Compensator ComprisingControlled Release and Expansion,” published Sep. 27, 2012, thedisclosure of which is incorporated by reference herein; U.S. PatentPub. No. 2013/0068816, entitled “Surgical Instrument and ButtressMaterial,” published Mar. 21, 2013, the disclosure of which isincorporated by reference herein; U.S. Pat. No. 9,999,408, entitled“Surgical Instrument with Fluid Fillable Buttress,” issued Jun. 19,2018, the disclosure of which is incorporated by reference herein; U.S.Pat. No. 8,814,025, entitled “Fibrin Pad Matrix with Suspended HeatActivated Beads of Adhesive,” issued Aug. 26, 2014, the disclosure ofwhich is incorporated by reference herein; U.S. Pat. No. 8,899,464,entitled “Attachment of Surgical Staple Buttress to Cartridge,” issuedDec. 2, 2014, the disclosure of which is incorporated by referenceherein; U.S. Pat. No. 9,492,170, entitled “Device for Applying Adjunctin Endoscopic Procedure,” issued Nov. 15, 2016, the disclosure of whichis incorporated by reference herein; U.S. Pat. No. 8,998,060, entitled“Resistive Heated Surgical Staple Cartridge with Phase Change Sealant,”issued Apr. 7, 2015, the disclosure of which is incorporated byreference herein; U.S. Pat. No. 9,393,018, entitled “Surgical StapleAssembly with Hemostatic Feature,” issued Jul. 19, 2016, the disclosureof which is incorporated by reference herein; U.S. Pat. No. 9,101,359,entitled “Surgical Staple Cartridge with Self-Dispensing StapleButtress,” issued Aug. 11, 2015, the disclosure of which is incorporatedby reference herein; U.S. Pat. No. 9,198,644, entitled “Anvil Cartridgefor Surgical Fastening Device,” issued Dec. 1, 2015, the disclosure ofwhich is incorporated by reference herein; U.S. Patent Pub. No.2013/0075447, entitled “Adjunct Therapy for Applying Hemostatic Agent,”published Mar. 28, 2013, the disclosure of which is incorporated byreference herein; U.S. Pat. No. 9,211,120, entitled “Tissue ThicknessCompensator Comprising a Plurality of Medicaments,” issued Dec. 15,2015, the disclosure of which is incorporated by reference herein; U.S.Patent Pub. No. 2015/0351758, entitled “Adjunct Materials and Methods ofUsing Same in Surgical Methods for Tissue Sealing,” published Dec. 10,2015, the disclosure of which is incorporated by reference herein; U.S.Patent Pub. No. 2017/0049444, entitled “Implantable Layers for aSurgical Instrument,” published Feb. 23, 2017, the disclosure of whichis incorporated by reference herein; U.S. Patent Pub. No. 2017/0055986,entitled “Drug Eluting Adjuncts and Methods of Using Drug ElutingAdjuncts,” published Mar. 2, 2017, the disclosure of which isincorporated by reference herein; U.S. Patent Pub. No. 2017/0086837,entitled “Compressible Adjunct with Crossing Spacer Fibers,” publishedMar. 30, 2017, the disclosure of which is incorporated by referenceherein; and/or U.S. Patent Pub. No. 2017/0086842, entitled “Method forApplying an Implantable Layer to a Fastener Cartridge,” published Mar.30, 2017, the disclosure of which is incorporated by reference herein.

Furthermore, buttress (5014) is configured to be cut by a knife (5114)(see FIG. 45A) from a proximal portion (5050) of buttress (5014), alongan intermediate portion (5052) of buttress (5014), and further through adistal portion (5054) of buttress (5014) such that inward edges areadjacent to cut tissue as discussed below in more detail. Buttress(5014) further includes a longitudinally extending pre-cut slit (5058)configured to receive knife (5114) (see FIG. 45A) and aid in separatinglateral portions of buttress (5014) as inward edges form therealong.Pre-cut slit (5058) thus also reduces wear on knife (5114) (see FIG.45A) during use.

Pre-cut slit (5058) of the present example has three distinct portionslongitudinally separated by core and outer layers (5044, 5046). Withrespect to FIG. 38 and FIG. 39, a proximal portion of pre-cut slit(5058) includes a proximal end slit (5060) in proximal end portion(5050) of buttress (5014) extending entirely through buttress (5014) ina transverse direction. An intermediate portion of pre-cut slit (5058)includes an intermediate slit (5062) in intermediate portion (5052) ofbuttress (5014) extending entirely through buttress (5014) in thetransverse direction. Furthermore, a distal portion of pre-cut slit(5058) includes a distal end slit (5064) extending entirely throughbuttress (5014) in the transverse direction. In the present example,proximal end slit (5060), intermediate slit (5062), and distal end slit(5064) are longitudinally aligned along a central longitudinal axis thatlaterally bifurcates lateral halves of buttress (5014). Intermediateslit (5062) is spaced apart from each of proximal and distal end slits(5060, 5064) such that the portions of buttress (5014) between slits(5060, 5062, 5064) remain uncut. Such uncut portions that may also bereferred to as “bridge” portions are sized large enough to remain intactduring assembly, storage, and application with tissue, but small enoughto substantially reduce resistance while cutting buttress (5014).However, it will be appreciated that some further perforation may beformed along the central longitudinal axis in alternative examples tofurther aid severability between lateral halves of buttress (5014).

Proximal end slit (5060) and distal end slit (5064) portions of pre-cutslit (5058) further include a proximal end opening (5068) and a distalend opening (5070), respectively. Proximal end opening (5068) ofproximal end slit (5060) widens symmetrically about the centrallongitudinal axis to a proximal end (5072) of buttress (5014), whereasdistal end opening (5070) of distal end slit (5064) widens symmetricallyabout the central longitudinal axis to a distal end (5074) of buttress(5014). Such widened proximal and distal end openings (5068, 5070) areconfigured to respectively aid knife's (5114) introduction and departurefrom buttress (5014) while cutting as discussed below in greater detail.

With respect to FIG. 40, upper adhesive layer (5042) is provided onouter layer (5046) of buttress (5014) in order to adhere buttress (5014)within effector (5112) (see FIG. 43A) of surgical instrument (5110) (seeFIG. 43A). Adherence of the buttress (5014) can occur through a varietyof mechanisms including but not limited to a pressure sensitiveadhesive. In some versions, each adhesive layer (5042) includes apressure sensitive adhesive material. Examples of various suitablematerials that may be used to form adhesive layers (5042) are disclosedin U.S. Patent Pub. No. 2016/0278774, entitled “Method of Applying aButtress to a Surgical Stapler,” published Sep. 29, 2016, the disclosureof which is incorporated by reference herein. Alternatively, any othersuitable materials may be used. As shown in the present example,adhesive layer (5042) is applied to form a continuous outer seal toenhance longevity once applied to end effector (5112) (see FIG. 43A).

It should be understood that the term “adhesive,” as used herein, mayinclude (but is not limited to) tacky materials and also materials thatare pliable or wax-like and adhere to a complex geometry via deformationand conformance. Some suitable adhesives may provide such pliability toadhere to a complex geometry via deformation and conformance withoutnecessarily providing a high initial tack. In some instances, adhesiveswith lower tackiness may be removed more cleanly from surfaces. Varioussuitable materials that may be used to form adhesive layers (5042) willbe apparent to those of ordinary skill in the art in view of theteachings herein.

As generally discussed above and with respect to FIGS. 38-42, upper andlower buttress assemblies (5012) are structurally identical. In thisrespect, FIG. 38 shows a lower surface of upper buttress assembly (5012)from a lower transverse direction, whereas FIG. 41 shows an uppersurface of lower buttress assembly (5012) from an upper transversedirection. These lower and upper surfaces of the present example havethe same lateral width and longitudinal lengths. Similarly, FIG. 40shows an upper surface of upper buttress assembly (5012) from an uppertransverse direction, whereas FIG. 42 shows an lower surface of lowerbuttress assembly (5012) from a lower transverse direction. In eachinstance in the present example, these lower and upper surfaces have thesame lateral width and longitudinal lengths. In addition, adhesivelayers (5042) of each respective buttress assembly (5012) are formed asadhesive bead layers (5042) in a predetermined adhesive pattern. Theadhesive pattern for each of the upper and lower buttress assemblies(5012) shown respectively in FIG. 40 and FIG. 42 is again identical,having the same lateral width and longitudinal lengths. The lateralwidth and longitudinal length of the adhesive pattern collectivelydefine an outer adhesive profile sized to accommodate both an anvil(5116) and a deck (5118) of a staple cartridge (5120). In other words,the outer adhesive profile of adhesive layer (5042) as well as buttress(5014) are interchangeable with anvil (5116) and deck (5118) such thatbuttress applier cartridge assembly (5010) may be used in an uprightorientation or flipped about the central longitudinal axis in anupside-down orientation while loading end buttress assemblies (5012) foruse.

To this end, FIG. 40 shows an outer anvil profile (5117) overlaid ontoupper buttress assembly (5012), and FIG. 42 shows an outer deck profile(5119) overlaid onto lower buttress assembly (5012) to illustrate theinterface between the adhesive pattern of adhesive layer (5042) with anunderside (5122) of anvil (5116) and deck (5118). The adhesive patternof the present example is symmetric about the central longitudinal axissuch that upper adhesive layer (5042) mirrors lower adhesive layer(5042) in lateral and longitudinal alignment when arranged offset fromeach other on platform (5030) (see FIG. 34). More particularly, eachadhesive layer (5042) of the present example has a lateral widthgenerally equivalent to the lateral width of outer deck profile (5119),but larger than the lateral width of outer anvil profile (5117).Adhesive layer (5042) thereby fits within outer deck profile (5119) ofFIG. 42 with a greater surface area contact to deck (5118) to increaseadhesive force therebetween. However, adhesive layer (5042) is laterallywider than outer anvil profile (5117) of FIG. 40 and extends laterallybeyond outer anvil profile (5117) with less surface area contact tounderside (5122) of anvil to decrease adhesive force therebetween. Moreparticularly, each adhesive layer (5042) of the present example has alateral width of approximately 0.41 inches. In contrast, deck (5118) iswider than underside (5122) of anvil (5116) with deck (5118) having alateral width of approximately 0.41 inches, and underside (5122) ofanvil (5116) having a lateral width of approximately 0.37 inches.

While the above referenced interchangeability between anvil (5116) anddeck (5118) simplifies loading buttress assemblies (5012) and reducesthe likelihood of improper loading, the reduced surface area contactbetween underside (5122) of anvil (5116) and adhesive layer (5042) easesremoval of buttress assembly (5012) from anvil (5116). In one example,underside (5122) of anvil (5116) is a relatively smooth material thatadheres to buttress (5014) via adhesive layer (5042) with a relativelyhigher adhesive force than the relatively lower adhesive force ofbuttress assembly (5012) to deck (5118). Decreasing the surface areacontact between adhesive layer (5042) and underside (5122) of anvil(5116) relative to the surface area contact with deck (5118) may thusresult in more equalized and/or predictable removal forces of buttressassemblies (5012) from anvil (5116) and deck (5118).

C. Exemplary Adhesion of Buttress to Surgical Stapler and Cutting ofButtress Assembly with Tissue

As noted above and discussed below in greater detail with respect toFIG. 43A, upper and lower buttress assemblies (5012) include upper andlower adhesive layers (5042) (or other form of adhesive material) toadhere respective buttresses (5014) to an underside (5122) of anvil(5116) and deck (5118) of staple cartridge (5120). Such adhesive mayprovide proper positioning of buttress (5014) before and duringactuation of end effector (5112); then allow buttress (5014) to separatefrom end effector (5112) after end effector (5112) has been actuated,without causing damage to buttress (5014) that is substantial enough tocompromise the proper subsequent functioning of buttress (5014).

To use buttress applier cartridge (5016) to load end effector (5112),the operator would first position buttress applier cartridge (5016) andend effector (5112) such that end effector (5112) is aligned with openend (5018) of buttress applier cartridge (5016) as shown in FIG. 43A.The operator would then advance end effector (5040) distally (and/orretract buttress applier cartridge (5016) proximally) to positionplatform (5030) and buttress assemblies (5012) between anvil (5116) andstaple cartridge (5120). In order to load buttress assemblies (5012) onend effector (5112), the operator simply closes end effector (5112) bypivoting anvil (5116) toward staple cartridge (5120) to reach the stateshown in FIG. 43B. As shown, closure of end effector (5040) results inanvil (5060) and staple cartridge (5120) bearing against actuator sleds(5032), thereby urging arms (5034) to unlock buttress assemblies (5012)from buttress applier cartridge (5016). Adhesive layers (5042) of upperand lower buttress assemblies (5012) are sufficiently compressed againstanvil (5116) and deck (5118) as shown in FIG. 43C to retain upper andlower buttress assemblies (5012) to end effector (5112) for staplingtissue.

To this end, FIGS. 44A-44C show a sequence where end effector (5112)loaded with buttress assemblies (5012) is actuated to drive a pluralityof staples (5124) through two apposed layers of tissue (T₁, T₂), withbuttress assemblies (5012) being secured to the same layers of tissue(T₁, T₂) by staples (5124). In particular, FIG. 44A shows layers oftissue (T₁, T₂) positioned between anvil (5116) and staple cartridge(5120), with anvil (5116) in the open position. Upper buttress assembly(5012) is adhered to the underside (5122) of anvil (5116) via adhesivelayer (5042); while lower buttress assembly (5012) is adhered to deck(5118) of staple cartridge (5120) via adhesive layer (5042). Layers oftissue (T₁, T₂) are thus interposed between upper and lower buttressassemblies (5012). Next, a trigger (not shown) is pivoted to drive anvil(5116) to the closed position as shown in FIG. 44B. At this stage,layers of tissue (T₁, T₂) are compressed between anvil (5116) and staplecartridge (5120), with upper and lower buttress assemblies (5012)engaging opposite surfaces of tissue layers (T₁, T₂). End effector(5112) is then actuated as described above, driving staple (5124)through upper and lower buttress assemblies (5012) and layers of tissue(T₁, T₂). As shown in FIG. 44C, a crown (5126) of driven staple (5124)captures and retains lower buttress assembly (5012) against layer oftissue (T₂). Deformed legs (5128) of staple (5124) capture and retainupper buttress assembly (5012) against layer of tissue (T₁).

It should be understood that a series of staples (5124) will similarlycapture and retain upper and lower buttress assemblies (5012) againstlayers of tissue (T₁, T₂), thereby securing upper and lower buttressassemblies (5012) to tissue (T₁, T₂). As can also be seen in FIGS.45A-45D, knife (5114) also cuts through a centerline of buttressassemblies (5012), separating each buttress assembly (5012) into acorresponding pair of sections, such that each section remains securedto a respective severed region of tissue (T₁, T₂). For example, withtissue (T₁, T₂) stapled as shown in FIG. 44C, knife (5114) is drivendistally from a proximal position severing tissue (T₁, T₂) and upper andlower buttress assemblies (5012).

FIGS. 45A-45D illustrate knife severing buttress assemblies (5012) andtissue (T₁, T₂) as shown in FIG. 44C, but with tissue (T₁, T₂), upperbuttress assembly (5012), and anvil (5116) hidden for additionalclarity. As shown in FIGS. 45A-45B, knife (5114) is introduced intoproximal end opening (5068) and further through the remainder ofproximal end slit (5060). Proximal end slit (5060) thereby inhibitsbuttress (5014) from gathering onto knife (5114) with staggered, unevencutting in the event that tissue (T₁, T₂) is not compressed againstproximal portion (5050) of buttress (5014).

With respect to FIG. 45C, knife (5114) distally translates from proximalend slit (5060) of pre-cut slit (5058) severing proximal andintermediate portions (5050, 5052) of buttress (5014) until receivedwithin intermediate slit (5062) of pre-cut slit (5058). Intermediateslit (5062) reduces the likelihood of inadvertently tearing intermediateand/or distal portions (5052, 5054) of buttress (5014) in the event thattissue (T₁, T₂) is only compressed against the proximal portion (5050)and not present against the intermediate and distal portions (5052,5054) of buttress (5014). As knife (5114) cuts from intermediate portion(5052) of buttress (5014) through distal portion (5054) of buttress(5014), FIG. 45D shown knife (5114) departing through distal end opening(5070) to the distal position having severed buttress assembly (5012)into a pair of lateral halves. Distal end slit (5064) is sized toaccommodate manufacturing tolerances associated with the particularposition of knife's (5114) distal position to ensure that buttressassembly (5012) is fully severed into two lateral halves upon completionwithout requiring the operator to manually rip or cut a remaining distalportion of buttress (5014).

With respect to FIG. 46, as end effector (5112) (see FIG. 45D) is pulledaway from tissue (T₁, T₂) after deploying staples (5124) and upper andlower buttress assemblies (5012), upper and lower buttress assemblies(5012) disengage end effector (5112), such that upper and lower buttressassemblies (5012) remain secured to tissue (T₁, T₂) with staples (5124).Buttressed tissue (T₁, T₂) thus provides structural reinforcement to thelines of staples (5124). In addition to the foregoing, it should also beunderstood that any of the various buttress assemblies described hereinmay be further constructed and operable in accordance with at least someof the teachings of U.S. Patent Pub. No. 2016/0278774, entitled “Methodof Applying a Buttress to a Surgical Stapler,” published Sep. 29, 2016,the disclosure of which is incorporated by reference herein.

VIII. Exemplary Buttress Applier Cartridge for Use with ButtressAssembly

In some instances, it may be desirable to use an exemplary buttressapplier cartridge assembly (7010) as shown in FIG. 47 to equip asurgical instrument with a buttress assembly (7012) for forming staplesin tissue with a buttress (7014). Such buttress (7014) inhibits theformed staples from pulling through the tissue to thereby reduce a riskof tissue tearing at or near the site of formed staples. In addition toor as an alternative to providing structural support and integrity to aline of staples, buttress (7014) may provide various other kinds ofeffects such as spacing or gap-filling, administration of therapeuticagents, and/or other effects. Prior to use with the surgical instrument,one or more buttresses (7014) is releasably retained on a buttressapplier cartridge (7016), which is configured to deposit buttressassembly (7010) onto surgical instrument for use as discussed below inmore detail in an exemplary surgical instrument (7018) (see FIG. 56A).

FIG. 47 shows buttress applier cartridge assembly (7010) including apair of buttress assemblies (7012) releasably retained on buttressapplier cartridge (7016), which supports and protects buttressassemblies (7012) prior to use and further aids with loading buttressassemblies (7012) on surgical instrument (7210) (see FIG. 56A). Buttressapplier cartridge (7016) of the present example includes an open end(7018) and a closed end (7020). Open end (7018) is configured to receiveend effector (7212) (see FIG. 56A) as described below in greater detail.Buttress applier cartridge (7016) further includes a housing assembly(7024) having an upper housing (7026) and a lower housing (7028), whicheach generally define a “U” shape to present open end (7018). Variouscomponents are interposed between upper and lower housings (7026, 7028).In particular, these components include a platform (7030) supporting achassis (7036).

Platform (7030) of the present example supports upper buttress assembly(7012) on one side of platform (7030) and lower buttress assembly (7012)on the other side of platform (7030). Platform (7030) is exposed inrecesses that are formed between the prongs of the “U” configuration ofupper and lower housings (7026, 7028). Thus, upper housing (7026) has anupper gap (7037) extending to the open end (7018) along an upper surfaceof platform (7030), and lower housing (7028) similarly has a lower gap(7038) extending to the open end (7018) along the lower surface ofplatform (7030). The location of platform (7030) and buttress assemblies(7012) in such recesses may prevent inadvertent contact between buttressassemblies (7012) and other devices in the operating room. In otherwords, upper and lower housings (7026, 7028) may provide some degree ofphysical shielding of buttress assemblies (7012) while buttressassemblies are retained on platform (7030).

Additional features may be combined as applicable with the followingexample of buttress applier cartridge assembly (7010). Such features aredescribed in U.S. Pat. App. No. [ATTORNEY DOCKET NO.END8634USNP.0663974], entitled “Adhesive Distribution on Buttress forSurgical Stapler,” filed on even date herewith; U.S. Pat. App. No.[ATTORNEY DOCKET NO. END8636USNP.0663978], entitled “Surgical StaplerButtress with Tissue In-Growth Promotion,” filed on even date herewith;U.S. Pat. App. No. [ATTORNEY DOCKET NO. END8635USNP.0663976], entitled“Configuration of Buttress for Surgical Stapler,” filed on even dateherewith; U.S. Pat. App. No. [ATTORNEY DOCKET NO. END8638USNP.0663983],entitled “Packaging for Surgical Stapler Buttress,” filed on even dateherewith; U.S. Pat. App. No. [ATTORNEY DOCKET NO. END9071USNP1.0714576],entitled “Method of Applying Buttresses to Surgically Cut and StapledSites,” filed on even date herewith; U.S. Pat. App. No. [ATTORNEY DOCKETNO. END9072USNP1.0714574], entitled “Curved Tip Surgical StaplerButtress Assembly Applicator with Opening Feature for Curved TipAlignment,” filed on even date herewith; U.S. Pat. App. No. [ATTORNEYDOCKET NO. END9073USNP1.0714572], entitled “Curved Tip Surgical StaplerButtress Assembly Applicator with Proximal Alignment Features,” filed oneven date herewith; and U.S. Pat. App. No. [ATTORNEY DOCKET NO.END9075USNP1.0714570], entitled “Curved Tip Surgical Stapler ButtressAssembly Applicator with Compression Layer Pocket Feature,” filed oneven date herewith, the disclosures of which are hereby incorporated byreference.

A. Exemplary Buttress Assembly

With respect to FIG. 47, upper and lower buttress assemblies (7012) arestructurally identical, but for the relative positions of upper andlower buttress assemblies (7012) retained on buttress applier cartridge(7016). Buttress applier cartridge assembly (7010) may thus be used inmore than one orientation with surgical instrument (7210) (see FIG.60A). It will be appreciated that the following description of upperbuttress assembly (7012) similarly applies to lower buttress assembly(7012) but for the respective orientations.

Upper buttress assembly (7012) includes buttress (7014) and an upperadhesive layer (7042). Buttress (7014) of the present example moreparticularly has a three-layer, polymer construction including a corelayer sandwiched between two outer layers to be collectively strong yetflexible to support a line of staples. In the present example, corelayer is a polyglactin 910 material, which is manufactured and sold byEthicon, Inc. of Somerville, N.J. as VICRYL, whereas each outer layer isa polydioxanone (PDO) film material. Buttress (7014) of the presentexample is formed by laminating core layer between outer layers under apredetermined pressure, a predetermined temperature, and a predeterminetime. Buttress (7014) is further mechanically cut to size therebyinhibiting abrasive edges, such as burrs and/or delamination, that coulddamage sensitive tissues. It will be appreciated that alternativemethods of cutting buttresses (7014), such as a laser cutting or hotknife cutting, may be similarly used.

By way of further example only, each buttress (7014) may comprise one ormore of the following: NEOVEIL absorbable PGA felt by Gunze Limited, ofKyoto, Japan; SEAMGUARD polyglycolic acid: trimethylene carbonate(PGA:TMC) reinforcement material by W.L. Gore & Associates, Inc., ofFlagstaff, Ariz.; PERI-STRIPS DRY with VERITAS Collagen Matrix (PSDV)reinforcement material, by Baxter Healthcare Corporation of Deerfield,Ill.; BIODESIGN biologic graft material by Cook Medical, Bloomington,Ind.; and/or SURGICEL NU-KNIT hemostat material by Ethicon, Inc. ofSomerville, N.J. Still other suitable materials that may be used to formeach buttress (7014) will be apparent to those of ordinary skill in theart in view of the teachings herein.

In addition or in the alternative, each buttress (7014) may comprise amaterial including, for example, a hemostatic agent such as fibrin toassist in coagulating blood and reduce bleeding at the severed and/orstapled surgical site along tissue. As another merely illustrativeexample, each buttress (7014) may comprise other adjuncts or hemostaticagents such as thrombin may be used such that each buttress (7014) mayassist to coagulate blood and reduce the amount of bleeding at thesurgical site. Other adjuncts or reagents that may be incorporated intoeach buttress (7014) may further include but are not limited to medicalfluid or matrix components. Merely illustrative examples of materialsthat may be used to form each buttress (7014), as well as materials thatmay be otherwise incorporated into each buttress (7014), are disclosedin U.S. patent application Ser. No. 14/667,842, entitled “Method ofApplying a Buttress to a Surgical Stapler,” filed Mar. 25, 2015, thedisclosure of which is incorporated by reference herein. Alternatively,any other suitable materials may be used.

By way of further example only, each buttress (7014) may be constructedin accordance with at least some of the teachings of U.S. Pat. Pub. No.2012/0241493, entitled “Tissue Thickness Compensator ComprisingControlled Release and Expansion,” published Sep. 27, 2012, thedisclosure of which is incorporated by reference herein; U.S. Pat. Pub.No. 2013/0068816, entitled “Surgical Instrument and Buttress Material,”published Mar. 21, 2013, the disclosure of which is incorporated byreference herein; U.S. Pat. No. 9,999,408, entitled “Surgical Instrumentwith Fluid Fillable Buttress,” issued Jun. 19, 2018, the disclosure ofwhich is incorporated by reference herein; U.S. Pat. No. 8,814,025,entitled “Fibrin Pad Matrix with Suspended Heat Activated Beads ofAdhesive,” issued Aug. 26, 2014, the disclosure of which is incorporatedby reference herein; U.S. Pat. No. 8,899,464, entitled “Attachment ofSurgical Staple Buttress to Cartridge,” issued Dec. 2, 2014, thedisclosure of which is incorporated by reference herein; U.S. Pat. No.9,492,170, entitled “Device for Applying Adjunct in EndoscopicProcedure,” issued Nov. 15, 2016, the disclosure of which isincorporated by reference herein; U.S. Pat. No. 8,998,060, entitled“Resistive Heated Surgical Staple Cartridge with Phase Change Sealant,”issued Apr. 7, 2015, the disclosure of which is incorporated byreference herein; U.S. Pat. No. 9,393,018, entitled “Surgical StapleAssembly with Hemostatic Feature,” issued Jul. 19, 2016, the disclosureof which is incorporated by reference herein; U.S. Pat. No. 9,101,359,entitled “Surgical Staple Cartridge with Self-Dispensing StapleButtress,” issued Aug. 11, 2015, the disclosure of which is incorporatedby reference herein; U.S. Pat. No. 9,198,644, entitled “Anvil Cartridgefor Surgical Fastening Device,” issued Dec. 1, 2015, the disclosure ofwhich is incorporated by reference herein; U.S. Pat. Pub. No.2013/0075447, entitled “Adjunct Therapy for Applying Hemostatic Agent,”published Mar. 28, 2013, the disclosure of which is incorporated byreference herein; U.S. Pat. No. 9,211,120, entitled “Tissue ThicknessCompensator Comprising a Plurality of Medicaments,” issued Dec. 15,2015, the disclosure of which is incorporated by reference herein; U.S.Pat. Pub. No. 2015/0351758, entitled “Adjunct Materials and Methods ofUsing Same in Surgical Methods for Tissue Sealing,” published Dec. 10,2015, the disclosure of which is incorporated by reference herein; U.S.Pat. Pub. No. 2017/0049444, entitled “Implantable Layers for a SurgicalInstrument,” published Feb. 23, 2017, the disclosure of which isincorporated by reference herein; U.S. Pat. Pub. No. 2017/0055986,entitled “Drug Eluting Adjuncts and Methods of Using Drug ElutingAdjuncts,” published Mar. 2, 2017, the disclosure of which isincorporated by reference herein; U.S. Pat. Pub. No. 2017/0086837,entitled “Compressible Adjunct with Crossing Spacer Fibers,” publishedMar. 30, 2017, the disclosure of which is incorporated by referenceherein; and/or U.S. Pat. Pub. No. 2017/0086842, entitled “Method forApplying an Implantable Layer to a Fastener Cartridge,” published Mar.30, 2017, the disclosure of which is incorporated by reference herein.

Furthermore, buttress (7014) is configured to be cut by a knife (notshown) from a proximal portion of buttress (7014), along an intermediateportion of buttress (7014), and further through a distal portion ofbuttress (7014) such that inward edges are adjacent to cut tissue asdiscussed below in more detail. Buttress (7014) further includes alongitudinally extending pre-cut slit (7044) configured to receive knife(not shown) and aid in separating lateral portions of buttress (7014) asinward edges form therealong.

Upper adhesive layer (7042) is provided on outer layer of buttress(7014) in order to adhere buttress (7014) within effector (7212) (seeFIG. 60A) of surgical instrument (7210) (see FIG. 60A). Adherence of thebuttress (7014) can occur through a variety of mechanisms including butnot limited to a pressure sensitive adhesive. In the case of pressuresensitive adhesion, adhesion occurs upon the application of at least apredetermined minimum force. In some versions, each adhesive layer(7042) includes a pressure sensitive adhesive material. Examples ofvarious suitable materials that may be used to form adhesive layers(7042) are disclosed in U.S. Pat. Pub. No. 2016/0278774, entitled“Method of Applying a Buttress to a Surgical Stapler,” published Sep.29, 2016, the disclosure of which is incorporated by reference herein.Alternatively, any other suitable materials may be used. As shown in thepresent example, adhesive layer (7042) is applied to form a continuousouter seal to enhance longevity once applied to end effector (7212) (seeFIG. 60A).

It should be understood that the term “adhesive,” as used herein, mayinclude (but is not limited to) tacky materials and also materials thatare pliable or wax-like and adhere to a complex geometry via deformationand conformance. Some suitable adhesives may provide such pliability toadhere to a complex geometry via deformation and conformance withoutnecessarily providing a high initial tack. In some instances, adhesiveswith lower tackiness may be removed more cleanly from surfaces. Varioussuitable materials that may be used to form adhesive layers (7042) willbe apparent to those of ordinary skill in the art in view of theteachings herein.

B. Exemplary Buttress Applier Cartridge

As shown in FIG. 48, buttress applier cartridge (7016) includes chassis(7036) supporting platform (7030) as well as upper and lower housings(7026, 7028) of housing assembly (7024) configured to connect togetherto define an interior space (7050). An upper left actuator sled (7052)and an upper right actuator sled (7054) are movably connected to anupper face chassis (7036) within interior space (7050), while a lowerleft actuator sled (7052) and a lower right actuator sled (7054) aremovably connected to a lower face of chassis (7036) within interiorspace (7050). Upper right and left actuator sleds (7052, 7054) retainupper buttress assembly (7012) on platform (7030) in a restraintposition, but are configured to move from the restraint position to arelease position for depositing the upper buttress assembly (7012) onend effector (7212) (see FIG. 60A). Similarly, lower right and leftactuator sleds (7052, 7054) retain lower buttress assembly (7012) onplatform (7030) in the restraint position, but are configured to movefrom the restraint position to the release position for depositing thelower buttress assembly (7012) on end effector (7212) (see FIG. 60A). Inthe present example, left actuator sled (7052) is distinct from rightactuator sled (7054) for reasons discussed below in greater detail.Also, upper and lower right actuator sleds (7052) are structurallyidentical to each other, and upper and lower left actuator sleds (7054)are structurally identical to each other. Thus, upper and lower actuatorsleds (7052, 7054) are interchangeable in this respect and anydiscussion contained herein directed to a pair of upper actuator sleds(7052, 7054) is similarly applicable to a pair of lower actuator sleds(7052, 7054).

Each actuator sled (7052, 7054) includes a plurality of arms (7055 a,7055 b, 7055 c) extending laterally inward to selectively and releasablysecure buttress assemblies (7012) to platform (7030). In particular,FIG. 48 show arms (7055 a, 7055 b, 7055 c) positioned such that buttressassemblies (7012) are interposed between the free ends of arms (7034)and platform (7030). Arms (7055 a, 7055 b, 7055 c) are movable laterallyoutwardly such that arms (7055 a, 7055 b, 7055 c) disengage buttressassemblies (7012) as shown in FIG. 48, thereby enabling buttressassemblies (7012) to be removed from platform (7030). In the presentexample, arms (7055 a, 7055 b, 7055 c) are configured to bear againstbuttress assemblies (7012) in the restraint position, thereby pinchingbuttress assemblies (7012) against platform (7030). Other suitable waysin which arms (7055 a, 7055 b, 7055 c) may engage buttress assemblies(7012) will be apparent to those of ordinary skill in the art in view ofthe teachings herein.

Chassis (7036) is configured to cooperate with upper and lower housings(7026, 7028) to provide a mechanical ground for moving components ofbuttress applier cartridge (7016) and provide structural support forcomponents of buttress applier cartridge (7016). Chassis (7036) furtherincludes integral gripping features (7056) that are exposed on oppositesides of housing assembly (7024). Gripping features (7056) have asurface geometry configured to promote an operator's grip of buttressapplier cartridge (7016) during use of buttress applier cartridge(7016). Various suitable configurations that may be used for grippingfeatures (7056) will be apparent to those of ordinary skill in the artin view of the teachings herein. Similarly, various surface treatments(e.g., elastomeric material, etc.) that may be applied to grippingfeatures (7056) will be apparent to those of ordinary skill in the artin view of the teachings herein.

With respect to FIG. 49, platform (7030) is connected to and supportedby chassis (7036) to secure platform (7030) relative to upper and lowerhousing (7026, 7028) (see FIG. 48). In the present example, platform(7030) is unitarily formed and molded to a rigid web portion (7058)including a frame (7060) and defining a plurality of holes (7062, 7064,7066) configured provide material overlap for mold securement. Holes(7062, 7064, 7066) more particularly include an upper and a lowerperipheral recess (7062) to the centrally located frame (7060). Acentral slot (7064) extends through frame (7060) as well as a pluralityof through holes (7066) spaced laterally about central slot (7064).Frame (7060) also extends laterally across central slot (7064) at bridgeportions (7068) to provide additional structural rigidity to chassis(7036) while providing platform (7030) with sufficient clearance forresilient deformation as discussed below in greater detail. Thereby,recess (7062), central slot (7064), and through holes (7066) receive aresilient, elastomeric material to form and secure the material asplatform (7030) to chassis (7036). While the present platform (7030) ismolded to chassis (7036), it will be appreciated that platform (7030)may be alternatively secured to chassis (7036), and the invention is notintended to be limited to the particular rigid web portion (7058) andmolding as discussed herein. Various suitable materials and structuralconfigurations that may be used to form platform (7030) will be apparentto those of ordinary skill in the art in view of the teachings herein.

Chassis (7036) further includes a plurality of sled clearance holes(7070) arranged in a pair of rows on opposing lateral sides of chassis(7036). Left and right actuator sleds (7052, 7054) (see FIGS. 53-56)connect together on opposing sides of chassis (7036) through such sledclearance holes (7070) to slide inwardly together in connected pairs.Additional details regarding connection and actuation of left and rightactuator sleds (7052, 7054) (see FIGS. 53-56) will be discussed below ingreater detail. However, it will be appreciated that any such holethrough chassis (7036) to provide for fastening clearance of left andright actuator sleds (7052, 7054) (see FIGS. 53-56) may be used, and theinvention is not intended to be unnecessarily limited to sled clearanceholes (7070) as discussed herein.

i. Exemplary Varying Stiffness Platform for Supporting ButtressAssemblies

FIGS. 49-52 show one example of platform (7030) in additional detail asincluding a pad (7072) having a peripheral securement (7074) laterallyextending therefrom and an anchor securement (7076) distally extendingtherefrom. Collectively, peripheral and anchor securements (7074, 7076)are positioned in recesses (7062) and extend into through holes (7066)to secure pad (7072) to chassis (7036). In some versions, platform(7030) is formed of a material that provides a high coefficient offriction, thereby reducing any tendency that buttress assemblies (7012)might otherwise have to slide along corresponding surfaces of platform(7030). For instance, platform (7030) may comprise a resilient,elastomeric material, such as silicone, to be molded to be formed asboth securements (7074, 7076) and pad (7072). One example siliconematerial is a 30 Durometer, Shore A silicone. To this end, pad (7072) isformed with varying stiffness along its longitudinal length tosimultaneously provide sufficient reactionary forces of at least thepredetermined minimum force for adhesion while accommodating aparallel-camber orientation, an over-camber orientation, and anunder-camber orientation of end effector (7212) (see FIG. 60A) asdiscussed below in greater detail. As used herein, the term“parallel-camber orientation” refers to an upper jaw and a lower jaw ofan end effector being functionally parallel to each other. The term“over-camber orientation” refers to an upper jaw of an end effectorbeing over rotated relative a lower jaw of an end effector. The term“under-camber orientation” refers to an upper jaw being under rotatedrelative to a lower jaw of an end effector. Exemplary upper and lowerjaws will be described in this context below in greater detail.

With respect to FIGS. 50-51, a resilient proximal end (7078) pad (7072)has a proximal end stiffness and a proximal transverse depth, whereas aresilient distal end (7080) of pad (7072) has a distal end stiffness anda distal transverse depth. In the present example, proximal endstiffness is generally greater than the distal end stiffness such thatinitial compression of distal end (7080) requires less compressive forcethan compression of proximal end (7078). Of course, further compressionof distal end (7080) relative to proximal end (7078) may result indistal end stiffness increasing to or even exceeding proximal endstiffness so long as the lesser stiffness of distal end (7080) isincluded therein for accommodating the over-cambered orientation of endeffector (7212) (see FIG. 60A).

In addition, distal transverse depth is greater than proximal transversedepth. Thereby, the greater distal transverse depth effectively props upbuttress assembly (7012) (see FIG. 47) for improved engagement with endeffector (7212) (see FIG. 56A) in the under-camber orientation, but thedecreased distal end stiffness allows for greater compression toaccommodate end effector (7212) (see FIG. 56A) in the over-camberorientation. Pad (7072) of the present example is wedge-shaped havingopposing ramp surfaces (7082) continuously tapering together from thedistal end (7080) to the proximal end (7078) for accommodatingparallel-camber, over-camber, and under-camber orientations along theentire longitudinal length of pad (7072). In some examples, depths andstiffnesses along pad (7072) are configured to receive a full range ofover-camber to under-camber orientations based on determinedmanufacturing tolerances of end effector (7011) (see FIG. 56A).

Pad (7072) shown in FIGS. 50-52 is unitarily formed of a resilientmaterial having a consistent stiffness throughout. Such longitudinallyvarying stiffness discussed above is thus generated by forming aplurality of reliefs, such as channels (7084), in at least the distalend (7080) to reduce the distal end stiffness relative to the proximalend stiffness. In the present example, channels (7084), such as fivechannels (7084) are equally spaced laterally apart from each other andlongitudinally extend from distal end (7080) to proximal end (7078).Channels (7084) further transversely extend to a base surface (7086)common to securements (7074, 7077) and proximal end (7078) to definevarying channel depths in the longitudinal direction along pad (7072).More particularly, upper channels (7084) extend transversely downwardfrom upper ramp surface (7082) to upper base surface (7086), whereaslower channels (7084) extend transversely upward from lower ramp surface(7082) to lower base surface (7086). In turn, a plurality of ribs (7088)are defined between channels (7084) and similarly extend from rampsurfaces (7082) to base surfaces (7086) to support buttress assemblies(7012) (see FIG. 47) and have varying stiffness from the proximal end(7078) to the distal end (7080) on each opposing side of pad (7072).

ii. Exemplary Restraint Features for Retention of Buttress

Assemblies on Varying Stiffness Platform

FIGS. 48 and 53-56 show restraint features, such as left and rightactuator sleds (7052, 7054) discussed briefly above for releasablysecuring buttress assemblies (7012) to platform (7030) in the restraintposition. Each of left and right actuator sleds (7052, 7054) has arms(7055 a, 7055 b, 7055 c) configured to accommodate varying transversedepths along the longitudinal length of pad (7072). More particularly,arms (7055 a, 7055 b, 7055 c) include a distal arm (7055 a), anintermediate arm (7055 b), and a proximal arm (7055 c) spacedlongitudinally apart from each other and extending laterally inwardtoward platform (7030). Each distal arm (7055 a), intermediate arm (7055b), and proximal arm (7055 c) of left or right actuator sled (7052,7054) transversely extends toward platform (7030) such that each ofdistal arm (7055 a), intermediate arm (7055 b), and proximal arm (7055c) is offset from the other arms (7055 a, 7055 b, 7055 c) in thetransverse direction. Thereby, distal arm (7055 a), intermediate arm(7055 b), and proximal arm (7055 c) are transversely spaced from theramp surface (7082) to trace the contour of the ramp surface (7082).

With respect to FIGS. 53-54, upper left actuator sled (7052) has alongitudinally extending upper left sled body (7090) with distal,intermediate, and proximal arms (7055 a, 7055 b, 7055 c) laterallyextending inward toward the right. Each arm (7055 a, 7055 b, 7055 c) ofleft actuator sled (7052) has a cam surface (7091) configured to receiveend effector (7212) (see FIG. 60A) thereagainst to urge left actuatorsled (7052) toward the release position. In addition, a pair of outerdowel holes (7092) open downward and are respectively positioned ondistal and proximal end portions of upper left sled body (7090). A pairof inner dowels (7094) extend downward from left sled body (7090)between outer dowel holes (7092) and in longitudinal alignment withouter dowel holes (7092). In order to arrest movement of upper leftactuator sled (7052) in the restraint and release positions, a distalcantilever catch (7096) laterally extends to the left from the distalportion of upper left sled body (7090), and a proximal cantilever catch(7096) laterally extends to the left from the proximal portion of upperleft sled body (7090). Distal and proximal cantilever catches (7096,7098) are respectively portions of distal and proximal detent couplings(7100, 7102) discussed below in greater detail.

With respect to FIGS. 55-56, upper right actuator sled (7054) has alongitudinally extending upper right sled body (7104) with distal,intermediate, and proximal arms (7055 a, 7055 b, 7055 c) laterallyextending inward toward the left. Each arm (7055 a, 7055 b, 7055 c) ofright actuator sled (7054) has a cam surface (7105) configured toreceive end effector (7212) (see FIG. 60A) thereagainst to urge leftactuator sled (7052) toward the release position. In addition, a pair ofinner dowel holes (7106) open downward and are positioned on upper rightsled body (7104). A pair of outer dowels (7108) extend downward fromright sled body (7104) and are respectively positioned on distal andproximal end portion of upper right sled body (7104) in longitudinalalignment with inner dowel holes (7106). In order to arrest movement ofupper right actuator sled (7054) in the restraint and release positions,another distal cantilever catch (7096) laterally extends to the rightfrom the distal portion of upper right sled body (7104), and anotherproximal cantilever catch (7096) laterally extends to the right from theproximal portion of upper right sled body (7104). Again, distal andproximal cantilever catches (7096, 7098) are respectively portions ofdistal and proximal detent couplings (7100, 7102) discussed below ingreater detail.

FIG. 48 and FIGS. 57-58 show upper right and left actuator sleds (7052,7054) as discussed above in detail as well as lower right and leftactuator sleds (7052, 7054). As briefly discussed above, the descriptionof upper right and left actuator sleds (7052, 7054) similarly applies tolower right and left actuator sleds (7052, 7054) with like featureshaving like numbers, but with reversed transverse directions (e.g.lower, upward, etc.). To this end, upper left actuator sled (7052) andlower right actuator sled (7054) connect together as outer dowels (7108)snap into outer dowel holes (7092) and inner dowels (7094) snap intoinner dowel holes (7106) with chassis (7036) positioned therebetween.Upper right actuator sled (7054) and lower left actuator sled (7052)similarly connect together as outer dowels (7108) snap into outer dowelholes (7092) and inner dowels (7094) snap into inner dowel holes (7106)with chassis (7036) positioned therebetween. Each of inner and outerdowels (7094, 7108) extend through sled clearance holes (7070) toslidably connect left and right actuator sleds (7052, 7054) to chassis(7036).

FIG. 58 shows one example of a pair of distal arms (7055 a), a pair ofintermediate arms (7055 b), and a pair of proximal arms (7055 c)respectively having platform (7030) positioned therebetween and tracingopposing ramp surfaces (7082). A central plane (7110) is shown in FIG.58 bisecting upper and lower portions of buttress applier cartridge(7016) through a central core of platform (7030). Distal arm (7055 a)has a distal retention surface (7112 a) transversely offset from centralplane (7110) a relatively greater distance, intermediate arm (7055 b)has an intermediate retention surface (7112 b) transversely offset fromcentral plane (7110) a relatively intermediate distance, and proximalarm (7055 c) has a proximal retention surface (7112 c) transverselyoffset from central plane (7110) a relatively lesser distance. Thereby,greater, intermediate, and lesser distances of distal, intermediate, andproximal retention surfaces (7112 a, 7112 b, 7112 c) trace ramp surfaces(7082) tapering from distal end (7080) of pad (7072) to proximal end(7078) of pad (7072). Thus, distal, intermediate, and proximal retentionsurfaces (7112 a, 7112 b, 7112 c) are offset in the transverse directionfrom each other and from central plane (7110). In the present example,each of distal arm (7055 a), intermediate arm (7055 b), and proximal arm(7055 c) are transversely spaced from the ramp surface (7082) an equaltransverse dimension such that arms (7055 a, 7055 b, 7055 c) equallytrace ramp surfaces (7082) tapering from distal end (7080) of pad (7072)to proximal end (7078) of pad (7072).

As shown in FIGS. 59A-59C, left and right actuator sleds (7052, 7054)are respectively urged outward from the restraint position to therelease position away from platform to disengage arms (7055 a, 7055 b,7055 c) from buttress assemblies (7012) (see FIG. 47) on platform (7030)as discussed herein. More particularly, distal and proximal detentcouplings (7100, 7102) releasably connected left and right actuatorsleds (7052, 7054) to chassis (7036) to arrest movement of left andright actuator sleds (7052, 7054) in the restraint position and therelease position. Distal and proximal detent couplings (7100, 7102)include distal and proximal cantilever catches (7096, 7098) extendingfrom each of left and right actuator sleds (7052, 7054) as discussedbriefly above. In addition, distal and proximal detent couplings (7100,7102) respectively further include distal and proximal ground cams(7114, 7116) extending from chassis (7036) in respective engagement withdistal and proximal cantilever catches (7096, 7098).

In the restraint position shown in FIG. 59A, each distal cantilevercatch (7096) is respectively engaged with each distal ground cam (7114),and each proximal cantilever catch (7098) is respectively engaged witheach proximal ground cam (7116) to urge left and right actuator sleds(7052, 7054) inward toward the restraint position. Directing left andright actuator sleds (7052, 7054) outward from the restraint positiontoward the release position as shown in FIG. 59B resiliently deflectsdistal and proximal cantilever catches (7096, 7098) as distal andproximal cantilever catches (7096, 7098) follow distal and proximalground cams (7114, 7116). As distal and proximal cantilever catches(7096, 7098) pass around distal and proximal ground cams (7114, 7116),distal and proximal cantilever catches (7096, 7098) reach a tippingpoint where distal and proximal cantilever catches (7096, 7098) urgeleft and right actuator sleds (7052, 7054) to the release position shownin FIG. 59C. In the release position, each distal cantilever catch(7096) is respectively engaged with each distal ground cam (7114), andeach proximal cantilever catch (7098) is respectively engaged with eachproximal ground cam (7116) to urge left and right actuator sleds (7052,7054) outward toward the release position. Thereby, distal and proximaldetent couplings (7100, 7102) effectively hold left and right actuatorsleds (7052, 7054) in the release position to inhibit arms (7055 a, 7055b, 7055 c) from inadvertently returning inward and catching buttressassembly (7012) (see FIG. 62) upon removal of end effector (7212) (seeFIG. 62) as discussed below in greater detail.

C. Exemplary Adhesion of Buttress to Surgical Stapler and Cutting ofButtress Assembly with Tissue

As noted above and discussed below in greater detail with respect toFIG. 60A, upper and lower buttress assemblies (7012) include upper andlower adhesive layers (7042) (or other form of adhesive material) toadhere respective buttresses (7014) to an underside (7216) of anvil(7218) and deck (7220) of staple cartridge (7222). Such adhesive mayprovide proper positioning of buttress (7014) before and duringactuation of end effector (7212); then allow buttress (7014) to separatefrom end effector (7212) after end effector (7212) has been actuated,without causing damage to buttress (7014) that is substantial enough tocompromise the proper subsequent functioning of buttress (7014).

To use buttress applier cartridge (7016) to load end effector (7212),the operator would first position buttress applier cartridge (7016) andend effector (7212) such that end effector (7212) is aligned with openend (7018) of buttress applier cartridge (7016) as shown in FIG. 60A.The operator would then advance end effector (7212) distally (and/orretract buttress applier cartridge (7016) proximally) to positionplatform (7030) and buttress assemblies (7012) between anvil (7218) andstaple cartridge (7222). In order to load buttress assemblies (7012) onend effector (7212), the operator simply closes end effector (7212) bypivoting anvil (7218) toward staple cartridge (7222) to reach the stateshown in FIG. 60B.

As shown, closure of end effector (7212) to the parallel-camberorientation results in anvil (7218) and staple cartridge (7222) bearingagainst actuator sleds (7032), thereby urging arms (7034) to unlockbuttress assemblies (7012) from buttress applier cartridge (7016).Adhesive layers (7042) of upper and lower buttress assemblies (7012) aresufficiently compressed against anvil (7218) and deck (7220) to retainupper and lower buttress assemblies (7012) to end effector (7212) forstapling tissue. Pad (7072) accommodates the parallel-camber orientationshown in FIG. 61 by providing reaction forces of at least thepredetermined minimum force for adhesion along the longitudinal lengthof buttress assemblies (7012). Upon depositing buttress assemblies(7012) onto anvil (7218) and staple cartridge (7222), the operatorremoves buttress applier cartridge (7016) from end effector (7212) asshown in FIG. 62.

To this end, FIGS. 63A-63C show a sequence where end effector (7212)loaded with buttress assemblies (7012) is actuated to drive a pluralityof staples (7224) through two apposed layers of tissue (T₁, T₂), withbuttress assemblies (7012) being secured to the same layers of tissue(T₁, T₂) by staples (7224). In particular, FIG. 63A shows layers oftissue (T₁, T₂) positioned between anvil (7218) and staple cartridge(7222), with anvil (7218) in the open position. Upper buttress assembly(7012) is adhered to the underside (7216) of anvil (7218) via adhesivelayer (7042); while lower buttress assembly (7012) is adhered to deck(7220) of staple cartridge (7222) via adhesive layer (7042). Layers oftissue (T₁, T₂) are thus interposed between upper and lower buttressassemblies (7012). Next, a trigger (not shown) is pivoted to drive anvil(7218) to the closed position as shown in FIG. 63B. At this stage,layers of tissue (T₁, T₂) are compressed between anvil (7218) and staplecartridge (7222), with upper and lower buttress assemblies (7012)engaging opposite surfaces of tissue layers (T₁, T₂). End effector(7212) is then actuated as described above, driving staple (7224)through upper and lower buttress assemblies (7012) and layers of tissue(T₁, T₂). As shown in FIG. 63C, a crown (7226) of driven staple (7224)captures and retains lower buttress assembly (7012) against layer oftissue (T₂). Deformed legs (7228) of staple (7224) capture and retainupper buttress assembly (7012) against layer of tissue (T₁).

It should be understood that a series of staples (7224) will similarlycapture and retain upper and lower buttress assemblies (7012) againstlayers of tissue (T₁, T₂), thereby securing upper and lower buttressassemblies (7012) to tissue (T₁, T₂). In one example, knife (not shown)cuts through a centerline of buttress assemblies (7012), separatingbuttress assemblies (7012) into a corresponding pair of sections, suchthat each section remains secured to a respective severed region oftissue (T₁, T₂) as shown in FIG. 64.

With respect to FIG. 64, as end effector (7212) (see FIG. 62) is pulledaway from tissue (T₁, T₂) after deploying staples (7224) and upper andlower buttress assemblies (7012), upper and lower buttress assemblies(7012) disengage end effector (7212), such that upper and lower buttressassemblies (7012) remain secured to tissue (T₁, T₂) with staples (7224).Buttressed tissue (T₁, T₂) thus provides structural reinforcement to thelines of staples (7224). In addition to the foregoing, it should also beunderstood that any of the various buttress assemblies described hereinmay be further constructed and operable in accordance with at least someof the teachings of U.S. Pat. Pub. No. 2016/0278774, entitled “Method ofApplying a Buttress to a Surgical Stapler,” published Sep. 29, 2016, thedisclosure of which is incorporated by reference herein.

FIGS. 65-66 show pad (7072) accommodating alternative camberorientations of end effector (7212), such as the over-camber orientationand the under-camber orientation. With respect to FIG. 65, closure ofend effector (7212) to the over-camber orientation results in anvil(7218) and staple cartridge (7222) unlocking buttress assemblies (7012)from buttress applier cartridge (7016) as discussed above. Adhesivelayers (7042) of upper and lower buttress assemblies (7012) aresufficiently compressed against anvil (7218) and deck (7220) to retainupper and lower buttress assemblies (7012) to end effector (7212) forstapling tissue. Pad (7072) accommodates the over-camber orientation byproviding reaction forces of at least the predetermined minimum forcefor adhesion along the longitudinal length of buttress assemblies(7012).

Similarly, FIG. 66 shows closure of end effector (7212) to theunder-camber orientation resulting in anvil (7218) and staple cartridge(7222) unlocking buttress assemblies (7012) from buttress appliercartridge (7016) as discussed above. Adhesive layers (7042) of upper andlower buttress assemblies (7012) are sufficiently compressed againstanvil (7218) and deck (7220) to retain upper and lower buttressassemblies (7012) to end effector (7212) for stapling tissue. Pad (7072)accommodates the under-camber orientation by providing reaction forcesof at least the predetermined minimum force for adhesion along thelongitudinal length of buttress assemblies (7012).

IX. Exemplary Surgical Stapler

FIGS. 67-73 depict an exemplary surgical stapling and severinginstrument (9010) that is sized for insertion, in a nonarticulated stateas depicted in FIG. 67, through a trocar cannula to a surgical site in apatient for performing a surgical procedure. By way of example only,such a trocar may be inserted in a patient's abdomen, between two of thepatient's ribs, or elsewhere. In some settings, instrument (9010) isused without a trocar. For instance, instrument (9010) may be inserteddirectly through a thoracotomy or other type of incision. Instrument(9010) of the present example includes a handle portion (9020) connectedto a shaft (9022). Shaft (9022) distally terminates in an articulationjoint (9011), which is further coupled with an end effector (9012). Itshould be understood that terms such as “proximal” and “distal” are usedherein with reference to a clinician gripping handle portion (9020) ofinstrument (9010). Thus, end effector (9012) is distal with respect tothe more proximal handle portion (9020). It will be further appreciatedthat for convenience and clarity, spatial terms such as “vertical,”“horizontal,” “upper,” and “lower” are used herein with respect to thedrawings. However, surgical instruments are used in many orientationsand positions, and these terms are not intended to be limiting andabsolute.

In some versions, shaft (9022) is constructed in accordance with atleast some of the teachings of U.S. Pat. No. 9,795,379, entitled“Surgical Instrument with Multi-Diameter Shaft,” issued Oct. 24, 2017,the disclosure of which is incorporated by reference herein. Othersuitable configurations for shaft (9022) will be apparent to those ofordinary skill in the art in view of the teachings herein.

Once articulation joint (9011) and end effector (9012) are insertedthrough the cannula passageway of a trocar, articulation joint (9011)may be remotely articulated, as depicted in phantom in FIG. 67, by anarticulation control (9013), such that end effector (9012) may bedeflected from the longitudinal axis (LA) of shaft (9022) at a desiredangle (a). End effector (9012) may thereby reach behind an organ orapproach tissue from a desired angle or for other reasons. In someversions, articulation joint (9011) enables deflection of end effector(9012) along a single plane. In some other versions, articulation joint(9011) enables deflection of end effector along more than one plane.Articulation joint (9011) and articulation control (9013) may beconfigured in accordance with the teachings of any of the numerousreferences that are cited herein. Alternatively, articulation joint(9011) and/or articulation control (9013) may have any other suitableconfiguration. By way of example only, articulation control (9013) mayinstead be configured as a knob that rotates about an axis that isperpendicular to the longitudinal axis (LA) of shaft (9022).

In some versions, articulation joint (9011) and/or articulation control(9013) are/is constructed and operable in accordance with at least someof the teachings of U.S. Pat. No. 9,186,142, entitled “SurgicalInstrument End Effector Articulation Drive with Pinion and OpposingRacks,” issued on Nov. 17, 2015, the disclosure of which is incorporatedby reference herein. Articulation joint (9011) may also be constructedand operable in accordance with at least some of the teachings of U.S.Pat. No. 9,795,379, entitled “Surgical Instrument with Multi-DiameterShaft,” issued Oct. 24, 2017, the disclosure of which is incorporated byreference herein. Other suitable forms that articulation joint (9011)and articulation control (9013) may take will be apparent to those ofordinary skill in the art in view of the teachings herein.

End effector (9012) of the present example includes a lower jaw (9016)and a pivotable anvil (9018). In the present example, anvil (9018) canalso be considered an upper jaw. Furthermore, in some versions like thepresent example, the upper jaw or anvil (9018) pivots with respect to astationary lower jaw (9016); however, in some other versions the upperjaw or anvil (9018) is stationary while the lower jaw (9016) pivots. Insome versions, lower jaw (9016) is constructed in accordance with atleast some of the teachings of U.S. Pat. No. 9,808,248, entitled“Installation Features for Surgical Instrument End Effector Cartridge,”issued Nov. 7, 2017, the disclosure of which is incorporated byreference herein. Anvil (9018) may be constructed in accordance with atleast some of the teachings of U.S. Pat. No. 9,517,065, entitled“Integrated Tissue Positioning and Jaw Alignment Features for SurgicalStapler,” issued Dec. 13, 2016, the disclosure of which is incorporatedby reference herein; U.S. Pat. No. 9,839,421, entitled “Jaw ClosureFeature for End Effector of Surgical Instrument,” issued Dec. 12, 2017,the disclosure of which is incorporated by reference herein; and/or atleast some of the teachings of U.S. Pat. No. 10,092,292, entitled“Staple Forming Features for Surgical Stapling Instrument,” issued Oct.9, 2018, the disclosure of which is incorporated by reference herein.Other suitable forms that lower jaw (9016) and anvil (9018) may takewill be apparent to those of ordinary skill in the art in view of theteachings herein.

Handle portion (9020) includes a pistol grip (9024) and a closuretrigger (9026). Closure trigger (9026) is pivotable toward pistol grip(9024) to cause clamping, or closing, of the anvil (9018) toward lowerjaw (9016) of end effector (9012). Such closing of anvil (9018) isprovided through a closure tube (9032) and a closure ring (9033), whichboth longitudinally translate relative to handle portion (9020) inresponse to pivoting of closure trigger (9026) relative to pistol grip(9024). Closure tube (9032) extends along the length of shaft (9022);and closure ring (9033) is positioned distal to articulation joint(9011). Articulation joint (9011) is operable to communicate/transmitlongitudinal movement from closure tube (9032) to closure ring (9033).

Handle portion (9020) also includes a firing trigger (9028). An elongatemember (not shown) longitudinally extends through shaft (9022) andcommunicates a longitudinal firing motion from handle portion (9020) toa firing beam (9014) in response to actuation of firing trigger (9028).This distal translation of firing beam (9014) causes the stapling andsevering of clamped tissue in end effector (9012), as will be describedin greater detail below. Thereafter, triggers (9026, 9028) may bereleased to release the tissue from end effector (9012).

FIGS. 69-72 depict end effector (9012) employing an E-beam form offiring beam (9014) to perform a number of functions. It should beunderstood that an E-beam form is just a merely illustrative example.Firing beam (9014) may take any other suitable form, including but notlimited to non-E-beam forms. As best seen in FIGS. 70A-70B, firing beam(9014) includes a transversely oriented upper pin (9038), a firing beamcap (9044), a transversely oriented middle pin (9046), and a distallypresented cutting edge (9048). Upper pin (9038) is positioned andtranslatable within a longitudinal anvil slot (9042) of anvil (9018).Firing beam cap (9044) slidably engages a lower surface of lower jaw(9016) by having firing beam (9014) extend through lower jaw slot (9045)(shown in FIG. 70B) that is formed through lower jaw (9016). Middle pin(9046) slidingly engages a top surface of lower jaw (9016), cooperatingwith firing beam cap (9044). Thereby, firing beam (9014) affirmativelyspaces end effector (9012) during firing.

Some non-E-beam forms of firing beam (9014) may lack upper pin (9038),middle pin (9046) and/or firing beam cap (9044). Some such versions ofinstrument (9010) may simply rely on closure ring (9033) or some otherfeature to pivot anvil (9018) to a closed position and hold anvil (9018)in the closed position while firing beam (9014) advances to the distalposition. By way of example only, firing beam (9014) and/or associatedlockout features may be constructed and operable in accordance with atleast some of the teachings of U.S. Pat. No. 9,717,497, entitled“Lockout Feature for Movable Cutting Member of Surgical Instrument,”issued Aug. 1, 2017, the disclosure of which is incorporated byreference herein. Other suitable forms that firing beam (9014) may takewill be apparent to those of ordinary skill in the art in view of theteachings herein.

FIG. 69 shows firing beam (9014) of the present example proximallypositioned and anvil (9018) pivoted to an open position, allowing anunspent staple cartridge (9037) to be removably installed into a channelof lower jaw (9016). As best seen in FIGS. 71-72, staple cartridge(9037) of this example includes a cartridge body (9070), which presentsan upper deck (9072) and is coupled with a lower cartridge tray (9074).As best seen in FIG. 69, a vertical slot (9049) is formed through partof staple cartridge (9037). As also best seen in FIG. 69, three rows ofstaple apertures (9051) are formed through upper deck (9072) on one sideof vertical slot (9049), with another set of three rows of stapleapertures (9051) being formed through upper deck (9072) on the otherside of vertical slot (9049). Of course, any other suitable number ofstaple rows (e.g., two rows, four rows, any other number) may beprovided. Referring back to FIGS. 70A-72, a wedge sled (9041) and aplurality of staple drivers (9043) are captured between cartridge body(9070) and tray (9074), with wedge sled (9041) being located proximal tostaple drivers (9043). Wedge sled (9041) is movable longitudinallywithin staple cartridge (9037); while staple drivers (9043) are movablevertically within staple cartridge (9037). Staples (9047) are alsopositioned within cartridge body (9070), above corresponding stapledrivers (9043). In particular, each staple (9047) is driven verticallywithin cartridge body (9070) by a staple driver (9043) to drive staple(9047) out through an associated staple aperture (9051). As best seen inFIGS. 70A-70B and 6, wedge sled (9041) presents inclined cam surfacesthat urge staple drivers (9043) upwardly as wedge sled (9041) is drivendistally through staple cartridge (9037).

In some versions, staple cartridge (9037) is constructed and operable inaccordance with at least some of the teachings of U.S. Pat. No.9,517,065, entitled “Integrated Tissue Positioning and Jaw AlignmentFeatures for Surgical Stapler,” issued Dec. 13, 2016, the disclosure ofwhich is incorporated by reference herein. In addition or in thealternative, staple cartridge (9037) may be constructed and operable inaccordance with at least some of the teachings of U.S. Pat. No.9,808,248, entitled “Installation Features for Surgical Instrument EndEffector Cartridge,” issued Nov. 7, 2017, the disclosure of which isincorporated by reference herein. Other suitable forms that staplecartridge (9037) may take will be apparent to those of ordinary skill inthe art in view of the teachings herein.

With end effector (9012) closed as depicted in FIGS. 70A-70B by distallyadvancing closure tube (9032) and closure ring (9033), firing beam(9014) is then advanced in engagement with anvil (9018) by having upperpin (9038) enter longitudinal anvil slot (9042). A pusher block (9080)(shown in FIG. 71) is located at the distal end of firing beam (9014)and is configured to engage wedge sled (9041) such that wedge sled(9041) is pushed distally by pusher block (9080) as firing beam (9014)is advanced distally through staple cartridge (9037) when firing trigger(9028) is actuated. During such firing, cutting edge (9048) of firingbeam (9014) enters vertical slot (9049) of staple cartridge (9037),severing tissue clamped between staple cartridge (9037) and anvil(9018). As shown in FIGS. 70A-70B, middle pin (9046) and pusher block(9080) together actuate staple cartridge (9037) by entering intovertical slot (9049) within staple cartridge (9037), driving wedge sled(9041) into upward camming contact with staple drivers (9043) that inturn drive staples (9047) out through staple apertures (9051) and intoforming contact with staple forming pockets (9053) (shown in FIG. 69) onthe inner surface of anvil (9018). FIG. 70B depicts firing beam (9014)fully distally translated after completing severing and stapling oftissue. It should be understood that staple forming pockets (9053) areintentionally omitted from the view in FIGS. 70A-70B; but staple formingpockets (9053) are shown in FIG. 69. It should also be understood thatanvil (9018) is intentionally omitted from the view in FIG. 71.

FIG. 73 shows end effector (9012) having been actuated through a singlestroke through tissue (9090). As shown, cutting edge (9048) (obscured inFIG. 73) has cut through tissue (9090), while staple drivers (9043) havedriven three alternating rows of staples (9047) through the tissue(9090) on each side of the cut line produced by cutting edge (9048).Staples (9047) are all oriented substantially parallel to the cut linein this example, though it should be understood that staples (9047) maybe positioned at any suitable orientations. In the present example, endeffector (9012) is withdrawn from the trocar after the first stroke iscomplete, spent staple cartridge (9037) is replaced with a new staplecartridge, and end effector (9012) is then again inserted through thetrocar to reach the stapling site for further cutting and stapling. Thisprocess may be repeated until the desired number of cuts and staples(9047) have been provided. Anvil (9018) may need to be closed tofacilitate insertion and withdrawal through the trocar; and anvil (9018)may need to be opened to facilitate replacement of staple cartridge(9037).

It should be understood that cutting edge (9048) may sever tissuesubstantially contemporaneously with staples (9047) being driven throughtissue during each actuation stroke. In the present example, cuttingedge (9048) just slightly lags behind driving of staples (9047), suchthat a staple (9047) is driven through the tissue just before cuttingedge (9048) passes through the same region of tissue, though it shouldbe understood that this order may be reversed or that cutting edge(9048) may be directly synchronized with adjacent staples. While FIG. 73shows end effector (9012) being actuated in two layers (9092, 9094) oftissue (9090), it should be understood that end effector (9012) may beactuated through a single layer of tissue (9090) or more than two layers(9092, 9094) of tissue. It should also be understood that the formationand positioning of staples (9047) adjacent to the cut line produced bycutting edge (9048) may substantially seal the tissue at the cut line,thereby reducing or preventing bleeding and/or leaking of other bodilyfluids at the cut line. Furthermore, while FIG. 73 shows end effector(9012) being actuated in two substantially flat, apposed planar layers(9092, 9094) of tissue, it should be understood that end effector (9012)may also be actuated across a tubular structure such as a blood vessel,a section of the gastrointestinal tract, etc. FIG. 73 should thereforenot be viewed as demonstrating any limitation on the contemplated usesfor end effector (9012). Various suitable settings and procedures inwhich instrument (9010) may be used will be apparent to those ofordinary skill in the art in view of the teachings herein.

In one version, instrument (9010) provides motorized control of firingbeam (9014). Exemplary components that may be used to provide motorizedcontrol of firing beam (9014) are shown and described in U.S. Pat. No.9,622,746, entitled “Distal Tip Features for End Effector of SurgicalInstrument,” issued Apr. 18, 2017, the disclosure of which isincorporated by reference herein. In addition to or in lieu of theforegoing, at least part of the motorized control may be configured inaccordance with at least some of the teachings of U.S. Pat. No.8,210,411, entitled “Motor-Driven Surgical Instrument,” issued Jul. 3,2012, the disclosure of which is incorporated by reference herein. Inaddition to or in lieu of the foregoing, the features operable to drivefiring beam (9014) may be configured in accordance with at least some ofthe teachings of U.S. Pat. No. 8,453,914, the disclosure of which isincorporated by reference herein; and/or in accordance with at leastsome of the teachings of U.S. Pat. No. 8,453,914, the disclosure ofwhich is also incorporated by reference herein. Other suitablecomponents, features, and configurations for providing motorization offiring beam (9014) will be apparent to those of ordinary skill in theart in view of the teachings herein. It should also be understood thatsome other versions may provide manual driving of firing beam (9014),such that a motor may be omitted. By way of example only, firing beam(9014) may be actuated in accordance with at least some of the teachingsof any other patent/publication reference cited herein.

Instrument (9010) may also include a lockout switch and lockoutindicator as shown and described in U.S. Pat. No. 9,622,746, entitled“Distal Tip Features for End Effector of Surgical Instrument,” issuedApr. 18, 2017, the disclosure of which is incorporated by referenceherein. Additionally, a lockout switch and/or lockout indication andassociated components/functionality may be configured in accordance withat least some of the teachings of U.S. Pat. No. 7,644,848, entitled“Electronic Lockouts and Surgical Instrument Including Same,” issuedJan. 12, 2010, the disclosure of which is incorporated by referenceherein.

Instrument (9010) also include a manual return switch (9116) configuredto act as a “bailout” feature, enabling the operator to quickly beginretracting firing beam (9014) proximally during a firing stroke. Inother words, manual return switch (9116) may be manually actuated whenfiring beam (9014) has only been partially advanced distally. Manualreturn switch (9116) may provide further functionality in accordancewith at least some of the teachings of U.S. Pat. No. 9,622,746, entitled“Distal Tip Features for End Effector of Surgical Instrument,” issuedApr. 18, 2017, the disclosure of which is incorporated by referenceherein.

In describing the operation of instrument (9010), use of the term“pivot” (and similar terms with “pivot” as a base) should not be read asnecessarily requiring pivotal movement about a fixed axis. In someversions, anvil (9018) pivots about an axis that is defined by a pin (orsimilar feature) that slides along an elongate slot or channel as anvil(9018) moves toward lower jaw (9016). In such versions, the pivot axistranslates along the path defined by the slot or channel while anvil(9018) simultaneously pivots about that axis. In addition or in thealternative, the pivot axis may slide along the slot/channel first, withanvil (9018) then pivoting about the pivot axis after the pivot axis hasslid a certain distance along the slot/channel. It should be understoodthat such sliding/translating pivotal movement is encompassed withinterms such as “pivot,” “pivots,” “pivotal,” “pivotable,” “pivoting,” andthe like. Of course, some versions may provide pivotal movement of anvil(9018) about an axis that remains fixed and does not translate within aslot or channel, etc.

It should be understood that instrument (9010) may be configured andoperable in accordance with any of the teachings of U.S. Pat. Nos.4,805,823; 5,415,334; 5,465,895; 5,597,107; 5,632,432; 5,673,840;5,704,534; 5,814,055; 6,978,921; 7,000,818; 7,143,923; 7,303,108;7,367,485; 7,380,695; 7,380,696; 7,404,508; 7,434,715; 7,721,930;8,408,439; and/or 8,453,914. As noted above, the disclosures of each ofthose patents and publications are incorporated by reference herein.Additional exemplary modifications that may be provided for instrument(9010) will be described in greater detail below. Various suitable waysin which the below teachings may be incorporated into instrument (9010)will be apparent to those of ordinary skill in the art. Similarly,various suitable ways in which the below teachings may be combined withvarious teachings of the patents/publications cited herein will beapparent to those of ordinary skill in the art. It should also beunderstood that the below teachings are not limited to instrument (9010)or devices taught in the patents cited herein. The below teachings maybe readily applied to various other kinds of instruments, includinginstruments that would not be classified as surgical staplers. Variousother suitable devices and settings in which the below teachings may beapplied will be apparent to those of ordinary skill in the art in viewof the teachings herein.

X. Exemplary End Effector with Visualization, Lead-In, and GatheringFeature

In some instances, it may be desirable to provide the user with bettervisualization of end effector (9012). In particular, as end effector(9012) is inserted into a surgical site, the user may rotate shaft(9022) of instrument (9010) during the procedure. As a result, endeffector (9012) also rotates. As end effector (9012) rotates, it may bedesirable for the user to have visual access to the surgical site. Forinstance, the user may wish to see the interface or contact betweentissue (9090) and end effector (9012). Since end effector (9012) may berotated about the longitudinal axis (LA) relative to handle portion(9020), the user may view the surgical site such that lower jaw (9016)of end effector is visible rather than anvil (9018). Alternatively, endeffector (9012) could be rotated such that when the user views endeffector (9012), anvil (9018) is visible by the user. It may bedesirable to provide visibility of the surgical site for the user beyondwhat is possible in instrument (9010) of FIG. 67. For instance, in thecase of some surgical procedures where fluid carrying vessels aretransected and stapled, it may be desirable to have visual confirmationthat anvil (9018) and lower jaw (9016) completely cover the vessel to becut, such that the vessel may be fully cut and stapled in one singleactuation. In other words, the user may wish to avoid cutting andstapling only a portion of a vessel. Thus, some means of visualmonitoring and/or feedback may be desirable so that the user will knowthat end effector (9012) has been positioned properly within thesurgical site for anvil (9018) and lower jaw (9016) to fully clamp thevessel. One potential way of monitoring the surgical site may includeimproving visualization of the area adjacent to the distal tip of lowerjaw (9016) and anvil (9018). Furthermore, not only visualization of thedistal end of end effector (9012) may be desirable, but also it may bedesirable to construct end effector (9012) such that the distal end ofanvil (9018) is configured to urge tissue (e.g., a large vessel)proximally into the space between anvil (9018) and lower jaw (9016) asanvil (9018) closes toward lower jaw (9016).

FIG. 74 depicts an exemplary end effector (9212) comprising an anvil(9218) and a lower jaw (9216). It will be appreciated that end effector(9212) may be used in place of end effector (9012) of instrument (9010).End effector (9212) may be integrally formed with instrument (9010) orin the alternative may be interchangeable with end effector (9012) ofinstrument (9010).

Anvil (9218) is operable to pivot relative to lower jaw (9216). Anvil(9218) and lower jaw (9216) may clamp tissue (9090) similarly toclamping performed by anvil (9018) and lower jaw (9016) shown in FIG.67. End effector (9212) further comprises a cartridge (9237) operable tobe placed in lower jaw (9216) similarly to cartridge (9037) shown inFIG. 69.

Anvil (9218) as can be seen in FIGS. 74-76 has an elongated shape wherethe distal portion of anvil (9218) angles toward cartridge (9237). Thedistal portion of anvil (9218) angles toward cartridge (9237) such thatthe distal most tip (9219) of anvil (9218) extends distallylongitudinally further than cartridge (9237). Though in some versions,distal tip (9219) may extend to a distance longitudinally equal tocartridge (9237) or proximal relative to the distal most point oncartridge (9237). Furthermore, anvil (9218) angles toward cartridge(9237) through a gentle slope. As seen best in FIG. 76, anvil (9218)includes sides (9241) that taper as they approach the distal most tip(9219) of anvil (9218). By way of example, anvil (9218) is shaped inFIG. 74 similarly to an inverted ski tip. The angled shape of anvil(9218) may provide easier insertion of end effector (9212) into asurgical site. For instance, the gentle slope or inverted ski tip shapeof anvil (9218) may provide an atraumatic tissue deflection surface asanvil (9218) contacts or moves through tissue. Such atraumatic tissuedeflection may include urging tissue (e.g., a large vessel) proximallyinto the space between anvil (9218) and lower jaw (9216) as anvil (9218)closes toward lower jaw (9216). Once placed into a surgical site, theangled shape of anvil (9218) may also provide better maneuverability ofend effector (9212) and better visibility of the distal end of endeffector (9212) in relation to anatomical structures at the surgicalsite. Other suitable variations of anvil (9218) will be apparent to oneof ordinary skill in the art in view of the teachings herein.

Cartridge (9237) is operable to hold staples similar to staples (9047)shown in FIG. 70A for driving into tissue. As shown in FIG. 75, thedistal end of cartridge (9237) has a triangular profile. In particular,the distal end of cartridge (9237) comprises an upper tapered surface(9239) and a lower tapered surface (9238). Additionally, the distal endof cartridge (9237) comprises a tapered side surface (9243) on eachside. In the present example, each tapered side surface (9243) ofcartridge (9237) generally aligns with the taper presented by sides(9241) of anvil (9218). Thus, as shown in FIG. 76, side surfaces (9243)of cartridge (9237) do not extend outwardly from longitudinal axis (LA)of end effector (9212) past sides (9241) of anvil (9218). Upper taperedsurface (9239) and lower tapered surface (9238) lead to the distal mostend of cartridge (9237). Lower tapered surface (9238) defines a sightline (9240) such that once end effector (9212) is inserted into asurgical site, the user can see along sight line (9240). Sight line(9240) extends along the edge of lower tapered surface (9238). It willbe appreciated that the planar shape of lower tapered surface (9238) maybe operable to allow the user to visualize and/or nearly visualize thedistal tip (9219) of anvil (9218). In particular, sight line (9240)intersects longitudinal axis (LA), which extends longitudinally throughend effector (9212), to form a viewing angle (θ).

Viewing angle (θ) may establish the relative visibility that a user hasregarding distal tip (9219). In particular, the user can see in front ofdistal tip (9219) along any line of sight that passes through theintersection of sight line (9240) and longitudinal axis (LA) withinviewing angle (θ). For instance, as viewing angle (θ) increases, theuser would have greater visibility of the area immediately in front ofdistal tip (9219) from proximal vantage points; whereas as viewing angle(θ) decreases, the user has less visibility of the area in front ofdistal tip (9219) from proximal vantage points. In some versions,viewing angle (θ) defines an angle greater than 90 degrees.Additionally, in some versions, viewing angle (θ) defines an anglegreater than 135 degrees. Other suitable angles for viewing angle (θ)will be apparent to one of ordinary skill in the art in view of theteachings herein. In the illustrated version, the user generally looksalong sight line (9240) or along some other line of sight within viewingangle (θ), thus, the user has visibility along sight line as well as anyarea within viewing angle (θ). The underside of distal tip (9219) isfurther slightly rounded to aid in the visibility of the intersection oflongitudinal axis (LA) and sight line (9240).

When tissue (9090) is clamped between a closed cartridge (9237) andanvil (9218), the user can look along sight line (9240) or elsewherewithin viewing angle (θ) to see, for instance, precisely where anvil(9218) has clamped tissue (9090). Furthermore, the user would be able todetermine whether the tissue is completely clamped between anvil (9218)and cartridge (9237) such that tissue does not spill over the end of endeffector (9212). The user may be able to also visualize the quality ofthe clamp between anvil (9218) and cartridge (9237) against tissue(9090). It will be appreciated that in some instances, end effector(9212) may be rotated before, during, or after clamping tissue (9090).As a result, the tapered shape of anvil (9218) may also provide moreaccessible viewing of distal tip (9219) or substantially adjacent distaltip (9219). The taper of anvil (9218) along with lower tapered surface(9238) of cartridge (9237) may further promote easy insertion of endeffector (9212) into tissue in an atraumatic manner. Furthermore, it maybe easier to fit end effector (9212) through a trocar or other devicesoperable to introduce end effector (9212) into a surgical site due tothe tapered end of end effector (9212). For instance, once distal tip(9219) is fit into a trocar, lower tapered surface (9238) and thetapered shape of anvil (9218) may provide a lead-in, guiding the rest ofend effector (9212) into the trocar. In view of the teachings herein,those of ordinary skill in the art will further appreciate thatvisibility and maneuverability can be enhanced by the tapered design forboth sides (9241) of anvil (9218) and each side (9243) of cartridge(9237).

In addition to the foregoing, end effector (9212) and versions ofinstrument (9010) incorporating end effector (9212) may be configuredand operable in accordance with at least some of the teachings of U.S.Pat. No. 9,186,142, entitled “Surgical Instrument End EffectorArticulation Drive with Pinion and Opposing Racks,” issued Nov. 17,2015, the disclosure of which is incorporated by reference herein; U.S.Pat. No. 9,717,497, entitled “Lockout Feature for Movable Cutting Memberof Surgical Instrument,” issued Aug. 1, 2017, the disclosure of which isincorporated by reference herein; U.S. Pat. No. 9,517,065, entitled“Integrated Tissue Positioning and Jaw Alignment Features for SurgicalStapler,” issued Dec. 13, 2016, the disclosure of which is incorporatedby reference herein; U.S. Pat. No. 9,839,421, entitled “Jaw ClosureFeature for End Effector of Surgical Instrument,” issued Dec. 12, 2017,the disclosure of which is incorporated by reference herein; U.S. Pat.No. 9,622,746, entitled “Distal Tip Features for End Effector ofSurgical Instrument,” issued Apr. 18, 2017, the disclosure of which isincorporated by reference herein; U.S. Pat. No. 10,092,292, entitled“Staple Forming Features for Surgical Stapling Instrument,” issued Oct.9, 20018, the disclosure of which is incorporated by reference herein;U.S. Pat. No. 9,795,379, entitled “Surgical Instrument withMulti-Diameter Shaft,” issued Oct. 24, 2017, the disclosure of which isincorporated by reference herein; and/or U.S. Pat. No. 9,808,248,entitled “Installation Features for Surgical Instrument End EffectorCartridge,” issued Nov. 7, 2017, the disclosure of which is incorporatedby reference herein. Further modifications that may be incorporated intoend effector (9212) will be described in greater detail below.

XI. Exemplary End Effectors with Bent or Angled Elastically DeformableAnvil Tips

In some procedures, it may be necessary to cut along tissue or throughtissue where more than one cutting sequence is necessary to complete theprocedure—in other words making sequential cuts along a continuous path.In such procedures, this sequential cutting technique can be defined as“marching.” With procedures that involve marching, instrument (9010) maybe placed at the surgical site, actuated to cut and staple, then removedfrom the surgical site for installing a new cartridge (9037), and thenbe placed back at the surgical site again for the next cut and staplealong the same path in which the previous cutting and stapling cycleoccurred. This process is repeated until the cut and staple procedure iscomplete. As can be seen in FIGS. 70A-70B and FIG. 73, the distal endconfiguration of end effector (9012) provides a gap between the distalend of anvil (9018) and the distal end of cartridge (9037). This gap mayfacilitate marching by providing an atraumatic space for tissue to enterthe distal end of end effector (9012) at the beginning of each marchingstep.

As noted above, the distal end configuration of end effector (9212) isdifferent from the distal end configuration of end effector (9012); withthe different configuration of end effector (9212) providing differentpotential advantages. In particular, the distal end configuration of endeffector (9212) may provide improved maneuverability and improvedvisibility of the relationship between the distal end of end effector(9212) and adjacent anatomical structures. In addition, the distal endconfiguration of end effector (9212) may provide tissue-gatheringeffects by urging tissue proximally into the space between anvil (9218)and lower jaw (9216) as anvil (9218) is closed toward lower jaw (9216).However, in versions where all the structures of end effector (9212) arerigid, the bent configuration of distal tip (9219) of anvil (9218) maynot lend itself well to marching operations, as distal tip (9219) mayimpart trauma to tissue that is not gathered into the space betweenanvil (9218) and lower jaw (9216) as anvil (9218) is closed toward lowerjaw (9216). Thus, in versions where all the structures of end effector(9212) are rigid, end effector (9212) may be best suited for cutting andstapling operations (e.g., vessel transection) where all of the tissuethat is to be cut and stapled is gathered proximal to distal tip (9219).

In view of the foregoing, it may be desirable to provide a variation ofend effectors (9012, 9212) that provides the marching capabilities ofend effector (9012), the improved visibility associated with endeffector (9212), and the tissue gathering capabilities of end effector(9212), without providing an increased risk of trauma that mightotherwise be associated with fully rigid versions of end effector(9212). The following describes several merely illustrative examples ofsuch variations of end effectors (9012, 9212). In the followingexamples, an anvil has a distal tip that is resiliently biased to assumea bent or angled configuration like distal tip (9219); yet theresiliently biased distal tip is deflectable away from the lower jaw inresponse to a sufficient load on the distal tip. It will be understoodin view of the teachings herein that providing an anvil with anelastically deformable angled distal tip portion can provide anadditional level of maneuverability benefits in terms of navigatingthrough tissue to a surgical site. In this manner, the deformable distaltip portion may deflect or deform to promote smooth and atraumaticmovement of the end effector through tissue, particularly duringmarching operations. Additionally, with an anvil having a bias to anangled position when not in a loaded state or contacted by surroundingtissue, enhanced visualization during tissue capture and cutting can beachieved compared to using end effectors with a straight or non-angledanvil. Moreover, an anvil with a distal tip that is biased to an angledposition may provide some degree of tissue gathering effects up untilreaching a load point that would be associated with marching rather thanbeing associated with simply gathering a relatively small tissuestructure between the anvil and lower jaw.

FIG. 77 shows another exemplary instrument (9310) configured as asurgical stapler. Instrument (9310) comprises a handle portion (9320)and a shaft (9322). Instrument (9310) has a modular configuration suchthat shaft (9322) is selectively removable from, and attachable to,handle portion (9320). Instrument (9310) is configured similarly toinstrument (9010) such that the operability and use of instrument (9310)is the same as described above for instrument (9010) with the addedfeature of instrument (9310) being a modular configuration. With itsmodular configuration, instrument (9310) provides a way to change theend effector. Such a change in the end effector may be made to replacean otherwise worn end effector, or to provide for a different endeffector configuration based on the procedure or user preference. Inaddition to or in lieu of the foregoing, features operable for providingthe modular configuration of instrument (9310) may be configured inaccordance with at least some of the teachings of U.S. Pub. No.2017/0086823, entitled “Surgical Stapling Instrument with Shaft Release,Powered Firing, and Powered Articulation,” published Mar. 30, 2017, thedisclosure of which is incorporated by reference herein. Other suitablecomponents, features, and configurations for providing instrument (9310)with a modular configuration will be apparent to those of ordinary skillin the art in view of the teachings herein. Moreover, it will beunderstood by those of ordinary skill in the art in view of theteachings herein, that instrument (9010) may be modified to incorporatea modular configuration as shown and described with respect toinstrument (9310) or other instruments incorporated by reference herein.

In the illustrated example of FIG. 77, instrument (9310) comprises anend effector (9312) having an anvil (9318) that has an angled distal tip(9319). Furthermore, distal tip (9319) of anvil (9318) is elasticallydeformable. In this manner, and as shown best in FIGS. 78A and 78B,angled distal tip (9319) is operable to elastically deform from a firstangled position to a second position. The second position for angleddistal tip (9319) may be substantially straight in some versions, butmay be angled to a degree (e.g., slightly above or slightly below thelongitudinal axis (A1) in other versions. It should be understood thatthe second position for angled distal tip (9319) may be defined by thecharacteristics (e.g., thickness, density, etc.) of the tissue that isbeing captured between anvil (9318) and lower jaw (9016). In the presentexample, end effector (9312) is provided on shaft (9322) that isdetachable from handle portion (9320). By way of example only, shaft(9322) may be detachable from handle portion (9320) in accordance withat least some of the teachings of U.S. Pat. No. 9,913,642, entitled“Surgical Instrument Comprising a Sensor System,” issued Mar. 13, 2018,the disclosure of which is incorporated by reference herein. In someother versions, shaft (9322) is not detachable from handle portion(9320).

It will be appreciated that end effector (9312) may be used in place ofend effector (9012) shown in FIG. 67. In some versions, end effector(9312) may be integrally formed with shaft (9022) or alternatively maybe separately formed and then combined. In some versions, end effector(9312) may be provided for use in robotic systems. In such roboticsystems, modular shaft (9322) having end effector (9312) may beattachable to a portion of the robotic system for use such that handleportion (9320) is replaced by components of the robotic system. Still inother examples, end effector (9312) may be adapted for use with arobotic system in a manner where end effector (9312) connects with therobotic system without necessarily connecting the entire modular shaft(9322). In view of the teachings herein, other ways to incorporate anend effector having an angled elastically deformable anvil tip into auser operated or robotic operated instrument will be apparent to thoseof ordinary skill in the art.

FIG. 78A shows an enlarged side view of the distal end of end effector(9312). End effector (9312) comprises anvil (9318) and lower jaw (9016)that accepts cartridge (9037) as described above with respect toinstrument (9010). Anvil (9318) pivotably rotates toward lower jaw(9016) in the same manner as anvil (9018) as described above withrespect to instrument (9010). In this configuration, end effector (9312)is similar to end effector (9012), however, anvil (9318) comprisesangled distal tip (9319) that is elastically deformable. As shown inFIG. 78A, tip (9319) is imparted with a bias to an angled position thatis shown in FIG. 77 and in phantom in FIG. 78A. Tip (9319) assumes thisangled position when end effector (9312) is not clamping tissue and isopen, as shown in FIG. 77; or closed without clamping tissue, as shownin phantom in FIG. 78A. In instances when end effector (9312) is in thisangled state or position, end effector (9312) can be considered notloaded or in a non-loaded state or position. Conversely when endeffector (9312) is clamping tissue, end effector (9312) can beconsidered loaded or in a loaded state or position.

When closed and not clamping tissue between anvil (9318) and lower jaw(9016), tip (9319) contacts cartridge (9037). In this position, anunderside surface (9324) of tip (9319) defines a plane that intersects alongitudinal axis (A1) defined by shaft (9322) to form an angle (θ1).When closed and clamping tissue (9090) between anvil (9318) and lowerjaw (9016), underside surface (9324) of tip (9319) contacts tissue(9090). In this position, underside surface (9324) of tip (9319) definesa plane that intersects longitudinal axis (A1) to form an angle (θ2). Inthe illustrated example of FIG. 78A, angles (01, 02) are relative tolongitudinal axis (A1), and the sum of angles (01, 02) represent therange of motion distal tip (9319) undergoes. By way of example only, andnot limitation, in some examples angle (θ1) is between about 20 andabout 70 degrees, or more particularly between about 30 degrees andabout 50 degrees, in a downward direction from longitudinal axis (A1)toward cartridge (9037). By way of example only, and not limitation, insome examples angle (θ2) is between about 0 and about 90 degrees in anupward direction from longitudinal axis (A1) away from cartridge (9037).By way of example only, and not limitation, in some examples the rangeof motion undergone by tip (9319) is between about 20 degrees and about110 degrees. The angles described for angles (01, 02) are exemplary onlyand not limiting. Other suitable angles will be apparent to those ofordinary skill in the art in view of the teachings herein.

Additionally, in some instances longitudinal axis (A1) represents azero-degree reference and angles relative thereto may be positive ornegative. For instance, where an angle is in a downward direction fromlongitudinal axis (A1) toward cartridge (9037), the angle may becharacterized as a negative angle. Similarly, where an angle is in anupward direction from longitudinal axis (A1) away from cartridge (9037),the angle may be characterized as a positive angle. When using theseconventions, the range of motion of distal tip (9319) due to deformationcan be understood as the sum of the absolute value of the angle whendistal tip (9319) is in the position contacting cartridge (9037), andthe angle when distal tip (9319) is in the deformed state when clampingtissue.

FIG. 78B shows another side view of an alternate end effector (9412)similar to end effector (9312) of FIG. 78A. With end effector (9312),when anvil (9318) is in its angled and non-deformed state (as seen inphantom in the view of FIG. 78A), anvil (9318) extends to a point evenwith or proximal to the distal most end of cartridge (9037). When anvil(9318) is deformed such that it is deflected upwardly, the end of distaltip (9319) extends to a point just distal to the distal most end ofcartridge (9037). With end effector (9412), as shown in FIG. 78B, whenanvil (9318) is in its angled and non-deformed state (as seen in phantomin the view of FIG. 78B), anvil (9318) extends to a point even with orproximal to the distal most end of cartridge (9037). When anvil (9318)is deformed such that it is deflected upwardly, the end of a distal tip(9319) of anvil (9318) extends to a point even with or proximal to thedistal most end of cartridge (9037). In this manner, anvil (9318) of endeffector (9412) remains even with or proximal to the distal most end ofcartridge (9037) when anvil (9318) is in its angled state or deformedstate such that anvil (9318) does not extend past the distal most end ofcartridge (9037) whether anvil (9318) is in its angled and non-deformedstate or in its deformed state. In some instances, this can be achievedby modifying anvil (9318) such that distal tip (9319) of anvil isshortened in length. In other instances, instruments (9010, 9310) may bemodified to provide for a slight proximal retraction of anvil (9318)when clamping. In view of the teachings herein, other ways to modify endeffector (9412) as it relates to control of anvil (9318) position, willbe apparent to those of ordinary skill in the art.

XII. Additional Exemplary End Effectors for Surgical Staplers

FIG. 79 illustrates another exemplary end effector (9512) that isconfigured for use with surgical stapling instruments as describedherein. End effector (9512) comprises an anvil (9518) and a lower jaw(9516). It will be appreciated that end effector (9512) may be used inplace of end effector (9012) of instrument (9010). End effector (9512)may be integrally formed with instrument (9010) or in the alternativemay be interchangeable with end effector (9012) of instrument (9010).

Anvil (9518) is operable to pivot relative to lower jaw (9516). Anvil(9518) and lower jaw (9516) may clamp tissue (9090) similarly toclamping performed by anvil (9018) and lower jaw (9016) shown in FIG.67. End effector (9512) further comprises a cartridge (9537) operable tobe placed in lower jaw (9516) similarly to cartridge (9037) shown inFIG. 69.

Anvil (9518) has an elongated shape where the distal portion of anvil(9518) angles toward cartridge (9537), such that anvil (9518) comprisesa curved tip. The distal portion of anvil (9518) angles toward cartridge(9537) such that the distal most tip (9519) of anvil (9518) extendsdistally longitudinally further than cartridge (9537). Though in someversions, distal tip (9519) may extend to a distance longitudinallyequal to cartridge (9537) or proximal relative to the distal most pointon cartridge (9537). Furthermore, distal portion of anvil (9518)includes sides (9541) that taper as they approach the distal most tip(9519) of anvil (9518). This shape of anvil (9518) may provide easierinsertion of end effector (9512) into a surgical site. For instance, theshape of anvil (9518) may provide an atraumatic tissue deflectionsurface as anvil (9518) contacts or moves through tissue. Suchatraumatic tissue deflection may include urging tissue (e.g., a largevessel) proximally into the space between anvil (9518) and lower jaw(9516) as anvil (9518) closes toward lower jaw (9516). Once placed intoa surgical site, the shape of anvil (9518) may also provide bettermaneuverability of end effector (9512) and better visibility of thedistal end of end effector (9512) in relation to anatomical structuresat the surgical site. Other suitable variations of anvil (9518) will beapparent to one of ordinary skill in the art in view of the teachingsherein.

Cartridge (9537) is operable to hold staples similar to staples (9047)shown in FIG. 70A for driving into tissue. The distal end of cartridge(9537) has a sloped profile. In particular, the distal end of cartridge(9537) comprises an upper tapered surface (9539), which leads to thedistal most end of cartridge (9537).

When tissue (9090) is clamped between a closed cartridge (9537) andanvil (9518), the user can look to see where anvil (9518) has clampedtissue (9090). Furthermore, the user can determine whether the tissue iscompletely clamped between anvil (9518) and cartridge (9537) such thattissue does not spill over the end of end effector (9512). The user maybe able to also visualize the quality of the clamp between anvil (9518)and cartridge (9537) against tissue (9090). It will be appreciated thatin some instances, end effector (9512) may be rotated before, during, orafter clamping tissue (9090). As a result, the shape of anvil (9518) mayalso provide more accessible viewing of distal tip (9519). The shape ofanvil (9518) and cartridge (9537) may further promote easy insertion ofend effector (9512) into tissue in an atraumatic manner. Furthermore, itmay be easier to fit end effector (9512) through a trocar or otherdevices operable to introduce end effector (9512) into a surgical sitedue to the tapered end of end effector (9512). For instance, once distaltip (9519) is fit into a trocar, the shape of anvil (9518) may provide alead-in, guiding the rest of end effector (9512) into the trocar. Inview of the teachings herein, those of ordinary skill in the art willfurther appreciate that visibility and maneuverability can be enhancedby the tapered design for both sides (9541) of the distal portion ofanvil (9518).

Still referring to FIG. 79, by way of example only, and not limitation,in one example of end effector (9512), the curved tip of anvil (9518)may be configured as a dissecting tip for separating tissue. In somesuch versions, such dissection of tissue may be accomplished using thecurved tip of anvil (9518). In such instances, the curved tip of anvil(9518) is a rigid structure without sharp cutting blades or surfaces anddissection occurs by the rigid curved tip separating and/or dissectingtissue that it contacts with sufficient force. In some versions wherethe curved tip of anvil (9518) is configured as a dissecting tip, thetip of the dissecting tip terminates between the planes defined by thetissue contacting surface and the bottom surface. Also, the tip of thedissecting tip is spaced from a distal end of the cartridge when the endeffector is in a closed position. In this manner, the curved tip isconfigured as a dissecting tip that can separate and/or dissect tissuewithout requiring engagement or interlocking of the anvil tip with thedistal end of the cartridge. Also in this manner, the curved tip isconfigured as a dissecting tip having a shape such that a user can slidethe tip behind certain tissue to separate and/or dissect the tissue itcontacts when sufficient force is applied. Of course having the curvedtip of anvil (9518) configured as a dissecting tip is not required inall versions of anvil (9518), and accordingly in other versions curvedtip of anvil (9518) can be an atraumatic tip or placement tip notconfigured to sever tissue as described above.

FIG. 80 illustrates another exemplary end effector (9612) that isconfigured for use with surgical stapling instruments as describedherein. End effector (9612) comprises an anvil (9618) and a lower jaw(9616). It will be appreciated that end effector (9612) may be used inplace of end effector (9012) of instrument (9010). End effector (9612)may be integrally formed with instrument (9010) or in the alternativemay be interchangeable with end effector (9012) of instrument (9010).

Anvil (9618) is operable to pivot relative to lower jaw (9616). Anvil(9618) and lower jaw (9616) may clamp tissue (9090) similarly toclamping performed by anvil (9018) and lower jaw (9016) shown in FIG.67. End effector (9612) further comprises a cartridge (9637) operable tobe placed in lower jaw (9616) similarly to cartridge (9037) shown inFIG. 69.

Anvil (9618) has an elongated shape where the distal portion of anvil(9618) angles toward cartridge (9637). The distal portion of anvil(9618) angles toward cartridge (9637) such that the distal most tip(9619) of anvil (9618) extends distally longitudinally further thancartridge (9637). Though in some versions, distal tip (9619) may extendto a distance longitudinally equal to cartridge (9637) or proximalrelative to the distal most point on cartridge (9637). Furthermore,distal portion of anvil (9618) includes sides (9641) that curve inwardas they approach the distal most tip (9619) of anvil (9618). This shapeof anvil (9618) may provide easier insertion of end effector (9612) intoa surgical site. For instance, the shape of anvil (9618) may provide anatraumatic tissue deflection surface as anvil (9618) contacts or movesthrough tissue. Such atraumatic tissue deflection may include urgingtissue (e.g., a large vessel) proximally into the space between anvil(9618) and lower jaw (9616) as anvil (9618) closes toward lower jaw(9616). Once placed into a surgical site, the shape of anvil (9618) mayalso provide better maneuverability of end effector (9612) and bettervisibility of the distal end of end effector (9612) in relation toanatomical structures at the surgical site. Other suitable variations ofanvil (9618) will be apparent to one of ordinary skill in the art inview of the teachings herein.

Cartridge (9637) is operable to hold staples similar to staples (9047)shown in FIG. 70A for driving into tissue. The distal end of cartridge(9637) has a sloped profile. In particular, the distal end of cartridge(9637) comprises an upper tapered surface (9639), which leads to thedistal most end of cartridge (9637).

When tissue (9090) is clamped between a closed cartridge (9637) andanvil (9618), the user can look to see where anvil (9618) has clampedtissue (9090). Furthermore, the user can determine whether the tissue iscompletely clamped between anvil (9618) and cartridge (9637) such thattissue does not spill over the end of end effector (9612). The user maybe able to also visualize the quality of the clamp between anvil (9618)and cartridge (9637) against tissue (9090). It will be appreciated thatin some instances, end effector (9612) may be rotated before, during, orafter clamping tissue (9090). As a result, the shape of anvil (9618) mayalso provide more accessible viewing of distal tip (9619). The shape ofanvil (9618) and cartridge (9637) may further promote easy insertion ofend effector (9612) into tissue in an atraumatic manner. Furthermore, itmay be easier to fit end effector (9612) through a trocar or otherdevices operable to introduce end effector (9612) into a surgical sitedue to the tapered end of end effector (9612). For instance, once distaltip (9619) is fit into a trocar, the shape of anvil (9618) may provide alead-in, guiding the rest of end effector (9612) into the trocar. Inview of the teachings herein, those of ordinary skill in the art willfurther appreciate that visibility and maneuverability can be enhancedby the curved design for both sides (9641) of the distal portion ofanvil (9618).

In addition to the foregoing, end effectors (9512, 9612) and versions ofinstrument (9010) incorporating end effectors (9512, 9612) may beconfigured and operable in accordance with at least some of theteachings of U.S. Pat. No. 9,186,142, entitled “Surgical Instrument EndEffector Articulation Drive with Pinion and Opposing Racks,” issued Nov.17, 2015, the disclosure of which is incorporated by reference herein;U.S. Pat. No. 9,717,497, entitled “Lockout Feature for Movable CuttingMember of Surgical Instrument,” issued Aug. 1, 2017, the disclosure ofwhich is incorporated by reference herein; U.S. Pat. No. 9,517,065,entitled “Integrated Tissue Positioning and Jaw Alignment Features forSurgical Stapler,” issued Dec. 13, 2016, the disclosure of which isincorporated by reference herein; U.S. Pat. No. 9,839,421, entitled “JawClosure Feature for End Effector of Surgical Instrument,” issued Dec.12, 2017, the disclosure of which is incorporated by reference herein;U.S. Pat. No. 9,622,746, entitled “Distal Tip Features for End Effectorof Surgical Instrument,” issued Apr. 18, 2017, the disclosure of whichis incorporated by reference herein; U.S. Pat. No. 10,092,292, entitled“Staple Forming Features for Surgical Stapling Instrument,” issued Oct.9, 20018, the disclosure of which is incorporated by reference herein;U.S. Pat. No. 9,795,379, entitled “Surgical Instrument withMulti-Diameter Shaft,” issued Oct. 24, 2017, the disclosure of which isincorporated by reference herein; and/or U.S. Pat. No. 9,808,248,entitled “Installation Features for Surgical Instrument End EffectorCartridge,” issued Nov. 7, 2017, the disclosure of which is incorporatedby reference herein. Further modifications that may be incorporated intoend effector (9212) will be described in greater detail below.

XIII Exemplary Buttress Loading and Application

FIGS. 81 and 82 illustrate an exemplary end effector (9040) configuredto apply a buttress to a tissue site where a cutting and staplingoperation is performed. End effector (9040) includes distal end (9141)and is connected with a shaft assembly (9030). End effector (9040)comprises an anvil (9060), a lower jaw (9050), and a staple cartridge(9170) received by lower jaw (9050). It will be appreciated that endeffector (9040) may be used in place of end effector (9012) ofinstrument (9010). End effector (9040) may be integrally formed withinstrument (9010) or in the alternative may be interchangeable with endeffector (9012) of instrument (9010).

FIGS. 81 and 82 also illustrate an exemplary buttress applicator (9200).Buttress applicator (9200) is configured to selectively retain buttressassemblies (9100, 9110). In the present example, buttress assembly(9100) is selectively retained on a top side of applicator (9200) andbuttress assembly (9110) is selectively retained on a bottom side ofapplicator (9200). In some other versions, applicator (9200) can beconfigured such that only one buttress assembly (9100, 9110) isselectively retained by buttress applicator (9200).

To use buttress applicator (9200) to load end effector (9040) withbuttress assemblies (9100, 9110), the operator would first positionapplicator (9200) and end effector (9040) such that end effector (9040)is aligned with an open end (9202) of applicator (9200) as shown in FIG.67. The operator would then advance end effector (9040) distally (and/orretract applicator (9200) proximally) to position buttress assemblies(9100, 9110) between anvil (9060) and staple cartridge (9170) as shownin FIG. 68. In order to load buttress assemblies (9100, 9110) on endeffector (9040), the operator may simply close end effector (9040) bypivoting anvil (9060) toward staple cartridge (9170). Closure of endeffector (9040) results in the distal ends of anvil (9060) and staplecartridge (9170) bearing against retaining features (9204) of buttressapplicator (9200) that are configured to selectively retain buttressassemblies (9100, 9110) with buttress applicator (9200). This contactdeflects such retaining features (9204) of buttress applicator (9200) tothereby permit contact between a surface of anvil (9060) and buttressassembly (9100) on one side of buttress applicator (9200), and a surfaceof staple cartridge (9170) and buttress assembly (9110) on another sideof buttress applicator (9200). Buttress assemblies (9100, 9110) comprisean adhesive on their respective surfaces such that with end effector(9040) clamping on both buttress assemblies (9100, 9110), buttressassemblies (9100, 9110) are adhered respectively to an underside ofanvil (9060) and a deck surface of staple cartridge (9170). End effector(9040) may then be re-opened (i.e., pivoting anvil (9060) away fromstaple cartridge (9170) and pulled away from buttress applicator (9200).With retaining features (9204) of applicator (9200) disengaged frombuttress assemblies (9100, 9110), end effector (9040) may freely pullbuttress assemblies (9100, 9110) away from buttress applicator (9200) asend effector (9040) is pulled away from buttress applicator (9200). Withbuttress assemblies (9100, 9110) loaded on end effector (9040), endeffector (9040) may then be used as described further below withreference to FIGS. 83A-84.

FIGS. 83A-83C show a sequence where an end effector (9040) that has beenloaded with buttress assemblies (9100, 9110) is actuated to drivestaples (9190) through two apposed layers of tissue (T₁, T₂), withbuttress assemblies (9100, 9110) being secured to the same layers oftissue (T₁, T₂) by staples (9190). In particular, FIG. 83A shows layersof tissue (T₁, T₂) positioned between anvil (9060) and staple cartridge(9170), with anvil (9060) in the open position. As shown, anvil (9060)comprises staple forming pockets (9064). Buttress assembly (9100) isadhered, via adhesive, to underside (9065) of anvil (9060); whilebuttress assembly (9110) is adhered, via adhesive, to deck (9073) ofstaple cartridge (9170). Layers of tissue (T₁, T₂) are thus interposedbetween buttress assemblies (9100, 9110). Next, end effector (9040) isclosed, which drives anvil (9060) to the closed position as shown inFIG. 83B. At this stage, layers of tissue (T₁, T₂) are compressedbetween anvil (9060) and staple cartridge (9170), with buttressassemblies (9100, 9110) engaging opposite surfaces of tissue layers (T₁,T₂). End effector (9040) is then actuated, whereby a staple driver(9075) drives staple (9190) through buttress assemblies (9100, 9110) andtissue layers (T₁, T₂). As shown in FIG. 83C, crown (9092) of drivenstaple (9190) captures and retains buttress assembly (9110) againstlayer of tissue (T₂). Deformed legs (9094) of staple (9190) capture andretain buttress assembly (9100) against layer of tissue (T₁).

It should be understood that a series of staples (9190) will similarlycapture and retain buttress assemblies (9100, 9110) against layers oftissue (T₁, T₂), thereby securing buttress assemblies (9100, 9110) totissue (T₁, T₂) as shown in FIG. 84. As end effector (9040) is pulledaway from tissue (9090) after deploying staples (9190) and buttressassemblies (9100, 9110), buttress assemblies (9100, 9110) disengage endeffector, such that buttress assemblies (9100, 9110) remain secured totissue (T₁, T₂) with staples (9190). Buttress assemblies (9100, 9110)thus provide structural reinforcement to the lines of staples (9190). Ascan also be seen in FIG. 84, a knife member (not shown) passes throughend effector (9040) and in doing so also cuts through a centerline ofbuttress assemblies (9100, 9110), separating each buttress assembly(9100, 9110) into a corresponding pair of sections, such that eachsection remains secured to a respective severed region of tissue (T₁,T₂).

In the foregoing example, buttress assembly (9100) is sized to spanacross the full width of underside (9065) of anvil (9060), such that aknife member (not shown) cuts through buttress assembly (9100) duringactuation of end effector (9040). In some other examples, buttressassembly (9100) is provided in two separate, laterally spaced apartportions, with one portion being disposed on underside (9065) of anvil(9060) on one half of anvil (9060) and another portion being disposed onunderside (9065) of anvil (9060) on the other half of anvil (9060). Insuch versions, the knife member (not shown) does not cut throughbuttress assembly (9100) during actuation of end effector (9040).

Likewise, buttress assembly (9110) may be sized to span across the fullwidth of deck (9073), such that the knife member (not shown) cutsthrough buttress assembly (9110) during actuation of end effector(9040). Alternatively, buttress assembly (9110) may be provided in twoseparate, laterally spaced apart portions, with one portion beingdisposed on deck (9073) on one half and another portion being disposedon deck (9073) on the other half. In such versions, the knife member(not shown) does not cut through buttress assembly (9110) duringactuation of end effector (9040).

In addition to the foregoing, it should also be understood that any ofthe various buttress assemblies described herein may be furtherconstructed and operable in accordance with at least some of theteachings of U.S. Pat. Pub. No. 2016/0278774, entitled “Method ofApplying a Buttress to a Surgical Stapler,” published Sep. 29, 2016, thedisclosure of which is incorporated by reference herein.

XIV. Exemplary Buttress Applier Cartridge Assembly

In some instances, it may be desirable to use an exemplary buttressapplier cartridge assembly (9710) as shown in FIG. 85 to equip asurgical instrument with a buttress assembly (9712) for forming staplesin tissue with a buttress (9714). In some instances, buttress appliercartridge assembly (9710) may be referred to as a buttress assemblyapplicator (9710). These terms as used herein should be understood to beinterchangeable. Buttress (9714) inhibits the formed staples frompulling through the tissue to thereby reduce a risk of tissue tearing ator near the site of formed staples. In addition to or as an alternativeto providing structural support and integrity to a line of staples,buttress (9714) may provide various other kinds of effects such asspacing or gap-filling, administration of therapeutic agents, and/orother effects. Prior to use with the surgical instrument, one or morebuttress assemblies (9712) is releasably retained on a buttress appliercartridge (9716), which is configured to deposit one or more buttressassemblies (9712) onto an end effector of a surgical instrument asdiscussed below.

FIG. 85 shows buttress applier cartridge assembly (9710) including apair of buttress assemblies (9712) releasably retained on buttressapplier cartridge (9716), which supports and protects buttressassemblies (9712) prior to use and further aids with loading buttressassemblies (9712) on surgical instrument (9010) (see FIG. 67). Buttressapplier cartridge (9716) of the present example includes an open end(9718) and a closed end (9720). Open end (9718) is configured to receivean end effector such as any of those end effectors described herein,including but not limited to end effectors (9012, 9212, 9312, 9412,9512, 9612). Buttress applier cartridge (9716) further includes ahousing assembly (9724) having an upper housing (9726) and a lowerhousing (9728), which each generally define a “U” shape to present openend (9718). Various components are interposed between upper and lowerhousings (9726, 9728). In particular, these components include a chassis(9736) supporting a platform (9730), which is also referred to as acompression layer (9730).

Platform or compression layer (9730) of the present example supportsupper buttress assembly (9712) on one side of platform (9730) and lowerbuttress assembly (9712) on the other side of platform (9730). Platform(9730) is exposed in recesses that are formed between the prongs of the“U” configuration of upper and lower housings (9726, 9728). Thus, upperhousing (9726) has an upper gap (9737) extending to the open end (9718)along an upper surface of platform (9730), and lower housing (9728)similarly has a lower gap (9738) extending to the open end (9718) alongthe lower surface of platform (9730). The location of platform (9730)and buttress assemblies (9712) in such recesses may prevent inadvertentcontact between buttress assemblies (9712) and other devices in theoperating room. In other words, upper and lower housings (9726, 9728)may provide some degree of physical shielding of buttress assemblies(9712) while buttress assemblies are retained on platform (9730).

Additional features may be combined as applicable with the followingexample of buttress applier cartridge assembly (9710). Such features aredescribed in U.S. Pat. App. No. [ATTORNEY DOCKET NO.END8634USNP.0663974], entitled “Adhesive Distribution on Buttress forSurgical Stapler,” filed on even date herewith; U.S. Pat. App. No.[ATTORNEY DOCKET NO. END8635USNP.0663976], entitled “Configuration ofButtress for Surgical Stapler,” filed on even date herewith; U.S. Pat.App. No. [ATTORNEY DOCKET NO. END8636USNP.0663978], entitled “SurgicalStapler Buttress with Tissue In-Growth Promotion,” filed on even dateherewith; U.S. Pat. App. No. [ATTORNEY DOCKET NO. END8638USNP.0663983],entitled “Packaging for Surgical Stapler Buttress,” filed on even dateherewith; U.S. Pat. App. No. [ATTORNEY DOCKET NO. END9075USNP1.0714570],entitled “Curved Tip Surgical Stapler Buttress Assembly Applicator withCompression Layer Pocket Feature,” filed on even date herewith; U.S.Pat. App. No. [ATTORNEY DOCKET NO. END9073USNP1.0714572], entitled“Curved Tip Surgical Stapler Buttress Assembly Applicator with ProximalAlignment Feature,” filed on even date herewith; U.S. Pat. App. No.[ATTORNEY DOCKET NO. END9071USNP1.0714576], entitled “Method of ApplyingButtresses to Surgically Cut and Stapled Sites,” filed on even dateherewith; U.S. Pat. App. No. [ATTORNEY DOCKET NO. END8639USDP.0663985],entitled “Applicator for Surgical Stapler Buttress,” filed on even dateherewith; U.S. Pat. App. No. [ATTORNEY DOCKET NO. END8640USDP.0663994],entitled “Buttress for Surgical Stapler,” filed on even date herewith;U.S. Pat. App. No. [ATTORNEY DOCKET NO. END8641USDP.0663996], entitled“Tray for Surgical Stapler Buttress Applicator,” filed on even dateherewith; U.S. Pat. App. No. [ATTORNEY DOCKET NO. END9080USDP1.0714568],entitled “Applicator for a Surgical Stapler Buttress,” filed on evendate herewith; and U.S. Pat. App. No. [ATTORNEY DOCKET NO.END9081USDP1.0714566], entitled “Buttress Assembly for a SurgicalStapler,” filed on even date herewith, the disclosures of which arehereby incorporated by reference.

A. Exemplary Buttress Assembly

With respect to FIG. 85, upper and lower buttress assemblies (9712) arestructurally identical, but for the relative positions of upper andlower buttress assemblies (9712) retained on buttress applier cartridge(9716). Buttress applier cartridge assembly (9710) may thus be used inmore than one orientation with surgical instrument (9010) and itsrespective end effectors that may be combined therewith. It will beappreciated that the following description of upper buttress assembly(9712) similarly applies to lower buttress assembly (9712) but for therespective orientations.

Upper buttress assembly (9712) includes buttress (9714) and an upperadhesive layer (9742). Buttress (9714) of the present example moreparticularly has a three-layer, polymer construction including a corelayer sandwiched between two outer layers to be collectively strong yetflexible to support a line of staples. In the present example, corelayer is a polyglactin 910 material, which is manufactured and sold byEthicon, Inc. of Somerville, N.J. as VICRYL, whereas each outer layer isa polydioxanone (PDO) film material. Buttress (9714) of the presentexample is formed by laminating core layer between outer layers under apredetermined pressure, a predetermined temperature, and a predeterminetime. Buttress (9714) is further mechanically cut to size therebyinhibiting abrasive edges, such as burrs and/or delamination, that coulddamage sensitive tissues. It will be appreciated that alternativemethods of cutting buttresses (9714), such as a laser cutting or hotknife cutting, may be similarly used.

By way of further example only, each buttress (9714) may comprise one ormore of the following: NEOVEIL absorbable PGA felt by Gunze Limited, ofKyoto, Japan; SEAMGUARD polyglycolic acid: trimethylene carbonate(PGA:TMC) reinforcement material by W.L. Gore & Associates, Inc., ofFlagstaff, Ariz.; PERI-STRIPS DRY with VERITAS Collagen Matrix (PSDV)reinforcement material, by Baxter Healthcare Corporation of Deerfield,Ill.; BIODESIGN biologic graft material by Cook Medical, Bloomington,Ind.; and/or SURGICEL NU-KNIT hemostat material by Ethicon, Inc. ofSomerville, N.J. Still other suitable materials that may be used to formeach buttress (9714) will be apparent to those of ordinary skill in theart in view of the teachings herein.

In addition or in the alternative, each buttress (9714) may comprise amaterial including, for example, a hemostatic agent such as fibrin toassist in coagulating blood and reduce bleeding at the severed and/orstapled surgical site along tissue. As another merely illustrativeexample, each buttress (9714) may comprise other adjuncts or hemostaticagents such as thrombin may be used such that each buttress (9714) mayassist to coagulate blood and reduce the amount of bleeding at thesurgical site. Other adjuncts or reagents that may be incorporated intoeach buttress (9714) may further include but are not limited to medicalfluid or matrix components. Merely illustrative examples of materialsthat may be used to form each buttress (9714), as well as materials thatmay be otherwise incorporated into each buttress (9714), are disclosedin U.S. Pub. No. 2016/0278774, entitled “Method of Applying a Buttressto a Surgical Stapler,” published Sep. 29, 2016, the disclosure of whichis incorporated by reference herein. Alternatively, any other suitablematerials may be used.

By way of further example only, each buttress (9714) may be constructedin accordance with at least some of the teachings of U.S. Pat. No.10,123,798, entitled “Tissue Thickness Compensator Comprising ControlledRelease and Expansion,” issued Nov. 13, 2018, the disclosure of which isincorporated by reference herein; U.S. Pat. Pub. No. 2013/0068816,entitled “Surgical Instrument and Buttress Material,” published Mar. 21,2013, the disclosure of which is incorporated by reference herein; U.S.Pat. No. 9,999,408, entitled “Surgical Instrument with Fluid FillableButtress,” issued Jun. 19, 2018, the disclosure of which is incorporatedby reference herein; U.S. Pat. No. 8,814,025, entitled “Fibrin PadMatrix with Suspended Heat Activated Beads of Adhesive,” issued Aug. 26,2014, the disclosure of which is incorporated by reference herein; U.S.Pat. No. 8,899,464, entitled “Attachment of Surgical Staple Buttress toCartridge,” issued Dec. 2, 2014, the disclosure of which is incorporatedby reference herein; U.S. Pat. No. 9,492,170, entitled “Device forApplying Adjunct in Endoscopic Procedure,” issued Nov. 15, 2016, thedisclosure of which is incorporated by reference herein; U.S. Pat. No.8,998,060, entitled “Resistive Heated Surgical Staple Cartridge withPhase Change Sealant,” issued Apr. 7, 2015, the disclosure of which isincorporated by reference herein; U.S. Pat. No. 9,393,018, entitled“Surgical Staple Assembly with Hemostatic Feature,” issued Jul. 19,2016, the disclosure of which is incorporated by reference herein; U.S.Pat. No. 9,101,359, entitled “Surgical Staple Cartridge withSelf-Dispensing Staple Buttress,” issued Aug. 11, 2015, the disclosureof which is incorporated by reference herein; U.S. Pat. No. 9,198,644,entitled “Anvil Cartridge for Surgical Fastening Device,” issued Dec. 1,2015, the disclosure of which is incorporated by reference herein; U.S.Pat. Pub. No. 2013/0075447, entitled “Adjunct Therapy for ApplyingHemostatic Agent,” published Mar. 28, 2013, the disclosure of which isincorporated by reference herein; U.S. Pat. No. 9,211,120, entitled“Tissue Thickness Compensator Comprising a Plurality of Medicaments,”issued Dec. 15, 2015, the disclosure of which is incorporated byreference herein; U.S. Pat. Pub. No. 2015/0351758, entitled “AdjunctMaterials and Methods of Using Same in Surgical Methods for TissueSealing,” published Dec. 10, 2015, the disclosure of which isincorporated by reference herein; U.S. Pat. Pub. No. 2017/0049444,entitled “Implantable Layers for a Surgical Instrument,” published Feb.23, 2017, the disclosure of which is incorporated by reference herein;U.S. Pat. Pub. No. 2017/0055986, entitled “Drug Eluting Adjuncts andMethods of Using Drug Eluting Adjuncts,” published Mar. 2, 2017, thedisclosure of which is incorporated by reference herein; U.S. Pat. Pub.No. 2017/0086837, entitled “Compressible Adjunct with Crossing SpacerFibers,” published Mar. 30, 2017, the disclosure of which isincorporated by reference herein; and/or U.S. Pat. Pub. No.2017/0086842, entitled “Method for Applying an Implantable Layer to aFastener Cartridge,” published Mar. 30, 2017, the disclosure of which isincorporated by reference herein.

Furthermore, buttress (9714) is configured to be cut by a knife (notshown) from a proximal portion of buttress (9714), along an intermediateportion of buttress (9714), and further through a distal portion ofbuttress (9714) such that inward edges are adjacent to cut tissue.Buttress (9714) further includes a longitudinally extending pre-cut slit(9744) configured to receive knife (not shown) and aid in separatinglateral portions of buttress (9714) as inward edges form therealong.

Upper adhesive layer (9742) is provided on outer layer of buttress(9714) in order to adhere buttress (9714) within end effectors describedherein. Adherence of the buttress (9714) can occur through a variety ofmechanisms including but not limited to a pressure sensitive adhesive.In the case of pressure sensitive adhesion, adhesion occurs upon theapplication of at least a predetermined minimum force. In some versions,each adhesive layer (9742) includes a pressure sensitive adhesivematerial. Examples of various suitable materials that may be used toform adhesive layers (9742) are disclosed in U.S. Pat. Pub. No.2016/0278774, entitled “Method of Applying a Buttress to a SurgicalStapler,” published Sep. 29, 2016, the disclosure of which isincorporated by reference herein. Alternatively, any other suitablematerials may be used. As shown in the present example, adhesive layer(9742) is applied to form a continuous outer seal to enhance longevityonce applied to an end effector.

It should be understood that the term “adhesive,” as used herein, mayinclude (but is not limited to) tacky materials and also materials thatare pliable or wax-like and adhere to a complex geometry via deformationand conformance. Some suitable adhesives may provide such pliability toadhere to a complex geometry via deformation and conformance withoutnecessarily providing a high initial tack. In some instances, adhesiveswith lower tackiness may be removed more cleanly from surfaces. Varioussuitable materials that may be used to form adhesive layers (9742) willbe apparent to those of ordinary skill in the art in view of theteachings herein.

B. Exemplary Buttress Applier Cartridge

As shown in FIG. 86, buttress applier cartridge (9716) includes chassis(9736) supporting platform (9730) as well as upper and lower housings(9726, 9728) of housing assembly (9724) configured to connect togetherto define an interior space (9750). An upper left actuator sled (9752)and an upper right actuator sled (9754) are movably connected to anupper face chassis (9736) within interior space (9750), while a lowerleft actuator sled (9752) and a lower right actuator sled (9754) aremovably connected to a lower face of chassis (9736) within interiorspace (9750). Upper right and left actuator sleds (9752, 9754) retainupper buttress assembly (9712) on platform (9730) in a restraintposition, but are configured to move from the restraint position to arelease position for depositing the upper buttress assembly (9712) on anend effector, such as any of the end effectors described herein.Similarly, lower right and left actuator sleds (9752, 9754) retain lowerbuttress assembly (9712) on platform (9730) in the restraint position,but are configured to move from the restraint position to the releaseposition for depositing the lower buttress assembly (9712) on an endeffector, such as any of the end effectors described herein. In thepresent example, left actuator sled (9752) is distinct from rightactuator sled (9754) for reasons discussed below in greater detail.Also, upper and lower right actuator sleds (9752) are structurallyidentical to each other, and upper and lower left actuator sleds (9754)are structurally identical to each other. Thus, upper and lower actuatorsleds (9752, 9754) are interchangeable in this respect and anydiscussion contained herein directed to a pair of upper actuator sleds(9752, 9754) is similarly applicable to a pair of lower actuator sleds(9752, 9754).

Each actuator sled (9752, 9754) includes a pair of arms (9755 a, 9755 b)extending laterally inward to selectively and releasably secure buttressassemblies (9712) to platform (9730). Arms (9755 a, 9755 b) may also bereferred to as retaining features or retention members, similar to theretaining features (9204) described above with respect to applicator(9200) in FIGS. 81 and 82. In particular, FIG. 86 show arms (9755 a,9755 b) positioned such that buttress assemblies (9712) are interposedbetween the free ends of arms (9755 a, 9755 b) and platform (9730). Arms(9755 a, 9755 b) are movable laterally outwardly such that arms (9755 a,9755 b) disengage buttress assemblies (9712), thereby enabling buttressassemblies (9712) to be removed from platform (9730). In the presentexample, arms (9755 a, 9755 b) are configured to bear against buttressassemblies (9712) in the restraint position, thereby pinching buttressassemblies (9712) against platform (9730). Other suitable ways in whicharms (9755 a, 9755 b) may engage buttress assemblies (9712) will beapparent to those of ordinary skill in the art in view of the teachingsherein.

Chassis (9736) is configured to cooperate with upper and lower housings(9726, 9728) to provide a mechanical ground for moving components ofbuttress applier cartridge (9716) and provide structural support forcomponents of buttress applier cartridge (9716). Chassis (9736) furtherincludes integral gripping features (9756) that are exposed on oppositesides of housing assembly (9724). Gripping features (9756) have asurface geometry configured to promote an operator's grip of buttressapplier cartridge (9716) during use of buttress applier cartridge(9716). Various suitable configurations that may be used for grippingfeatures (9756) will be apparent to those of ordinary skill in the artin view of the teachings herein. Similarly, various surface treatments(e.g., elastomeric material, etc.) that may be applied to grippingfeatures (9756) will be apparent to those of ordinary skill in the artin view of the teachings herein.

With respect to FIG. 87, platform (9730) is connected to and supportedby chassis (9736) to secure platform (9730) relative to upper and lowerhousing (9726, 9728). In the present example, platform (9730) isunitarily formed and molded to a rigid web portion (9758) including aframe (9760) and defining a plurality of holes (9762, 9764, 9766)configured provide material overlap for mold securement. Holes (9762,9764, 9766) more particularly include an upper slot (9762) and centralslot (9764) that extend through frame (9760) as well as a plurality ofthrough holes (9766) spaced laterally about slot (9762, 9764). Frame(9760) also extends laterally across central slot (9764) at bridgeportions (9768) to provide additional structural rigidity to chassis(9736) while providing platform (9730) with sufficient clearance forresilient deformation as discussed below in greater detail. Thereby,slots (9762, 9764) and through holes (9766) receive a resilient,elastomeric material to form and secure the material as platform (9730)to chassis (9736). While the present platform (9730) is molded tochassis (9736), it will be appreciated that platform (9730) may bealternatively secured to chassis (9736), and thus the attachment ofplatform (9730) to chassis (9736) is not intended to be limited to theparticular rigid web portion (9758) and molding as discussed herein.Various suitable materials and structural configurations that may beused to form platform (9730) will be apparent to those of ordinary skillin the art in view of the teachings herein.

Chassis (9736) further includes a plurality of sled clearance holes(9770) arranged in a pair of rows on opposing lateral sides of chassis(9736). Left and right actuator sleds (9752, 9754) connect together onopposing sides of chassis (9736) through such sled clearance holes(9770) to slide inwardly together in connected pairs. Additional detailsregarding connection and actuation of left and right actuator sleds(9752, 9754) will be discussed below in greater detail. However, it willbe appreciated that any such hole through chassis (9736) to provide forfastening clearanceF of left and right actuator sleds (9752, 9754) maybe used, and the invention is not intended to be unnecessarily limitedto sled clearance holes (9070) as discussed herein.

i. Exemplary Varying Stiffness Platform for Supporting ButtressAssemblies

FIGS. 88-90 show one example of platform (9730) in additional detail asincluding a pad (9772) and perimeter region (9774) laterally extendingtherefrom. Perimeter region (9774) is positioned in within frame (9760)and extends into through holes (9766) to secure pad (9772) to chassis(9736). In some versions, platform (9730) is formed of a material thatprovides a high coefficient of friction, thereby reducing any tendencythat buttress assemblies (9712) might otherwise have to slide alongcorresponding surfaces of platform (9730). For instance, platform (9730)may comprise a resilient, elastomeric material, such as silicone, to bemolded to be formed as securement (9774) and pad (9772). One examplesilicone material is a 30 Durometer, Shore A silicone. To this end, pad(9772) is formed with varying stiffness along its longitudinal length tosimultaneously provide sufficient reactionary forces of at least thepredetermined minimum force for adhesion while accommodating aparallel-camber orientation, an over-camber orientation, and anunder-camber orientation of an end effector as discussed below ingreater detail. As used herein, the term “parallel-camber orientation”refers to an upper jaw and a lower jaw of an end effector beingfunctionally parallel to each other. The term “over-camber orientation”refers to an upper jaw of an end effector being over rotated relative alower jaw of an end effector. The term “under-camber orientation” refersto an upper jaw being under rotated relative to a lower jaw of an endeffector.

With respect to FIGS. 88 and 89, a resilient proximal end (9778) of pad(9772) has a proximal end stiffness and a proximal transverse depth,whereas a resilient distal end (9780) of pad (9772) has a distal endstiffness and a distal transverse depth. In the present example,proximal end stiffness is generally greater than the distal endstiffness such that initial compression of distal end (9780) requiresless compressive force than compression of proximal end (9778). Ofcourse, further compression of distal end (9780) relative to proximalend (9778) may result in distal end stiffness increasing to or evenexceeding proximal end stiffness so long as the lesser stiffness ofdistal end (9780) is included therein for accommodating theover-cambered orientation of an end effector.

In addition, distal transverse depth is greater than proximal transversedepth. Thereby, the greater distal transverse depth effectively props upbuttress assembly (9712) for improved engagement with an end effector inthe under-camber orientation, but the decreased distal end stiffnessallows for greater compression to accommodate an end effector in theover-camber orientation. Pad (9772) of the present example iswedge-shaped having opposing ramp surfaces (9782) continuously taperingtogether from the distal end (9780) to the proximal end (9778) foraccommodating parallel-camber, over-camber, and under-camberorientations along the entire longitudinal length of pad (9772). In someexamples, depths and stiffnesses along pad (9772) are configured toreceive a full range of over-camber to under-camber orientations basedon determined manufacturing tolerances of an end effector.

Pad (9772) shown in FIGS. 88-90 is unitarily formed of a resilientmaterial having a consistent stiffness throughout. Such longitudinallyvarying stiffness discussed above is thus generated by forming aplurality of reliefs, such as channels (9784), in at least the distalend (9780) to reduce the distal end stiffness relative to the proximalend stiffness. In the present example, channels (9784), such as fivechannels (9784) are equally spaced laterally apart from each other andlongitudinally extend from distal end (9780) to proximal end (9778).Channels (9784) further define varying channel depths in thelongitudinal direction along pad (9772). More particularly, upperchannels (9784) extend transversely downward from upper ramp surface(9782) to upper base surface (9786), whereas lower channels (9784)extend transversely upward from lower ramp surface (9782) to lower basesurface (9786). In turn, a plurality of ribs (9788) are defined betweenchannels (9784) and similarly extend from ramp surfaces (9782) to basesurfaces (9786) to support buttress assemblies (9712) and have varyingstiffness from the proximal end (9778) to the distal end (9780) on eachopposing side of pad (9772).

ii. Exemplary Restraint Features for Retention of Buttress Assemblies onVarying Stiffness Platform

FIGS. 86 and 91-94 show restraint features, such as left and rightactuator sleds (9752, 9754) discussed briefly above for releasablysecuring buttress assemblies (9712) to platform (9730) in the restraintposition. Each of left and right actuator sleds (9752, 9754) has arms(9755 a, 9755 b) configured to accommodate varying transverse depthsalong the longitudinal length of pad (9772). More particularly, arms(9755 a, 9755 b) include a distal arm (9755 a) and a proximal arm (9755b) spaced longitudinally apart from each other and extending laterallyinward toward platform (9730). Each distal arm (9755 a) and proximal arm(9755 b) of left or right actuator sled (9752, 9754) transverselyextends toward platform (9730) such that each of distal arm (9755 a) andproximal arm (9755 b) is offset from the other arms (9755 a, 9755 b) inthe transverse direction. Thereby, distal arm (9755 a) and proximal arm(9755 b) are transversely spaced from the ramp surface (9782) to tracethe contour of the ramp surface (9782).

With respect to FIGS. 91 and 92, upper left actuator sled (9752) has alongitudinally extending upper left sled body (9790) with distal andproximal arms (9755 a, 9755 b) laterally extending inward toward theright. Each arm (9755 a, 9755 b) of left actuator sled (9752) has a camsurface (9791) configured to receive an end effector thereagainst tourge left actuator sled (9752) toward the release position. In addition,a dowel hole (9792) opens downward and is respectively positioned on aportion of upper left sled body (9790). A dowel (9794) extends downwardfrom left sled body (9790) and in longitudinal alignment with outerdowel hole (9792). In order to arrest movement of upper left actuatorsled (9752) in the restraint and release positions, a distal cantilevercatch (9796) laterally extends to the left from the distal portion ofupper left sled body (9790), and a proximal cantilever catch (9798)laterally extends to the left from the proximal portion of upper leftsled body (9790). Distal and proximal cantilever catches (9796, 9798)are respectively portions of distal and proximal detent couplings (9800,9802) discussed below in greater detail.

With respect to FIGS. 93 and 94, upper right actuator sled (9754) has alongitudinally extending upper right sled body (9804) with distal andproximal arms (9755 a, 9755 b) laterally extending inward toward theleft. Each arm (9755 a, 9755 b) of right actuator sled (9754) has a camsurface (9805) configured to receive an end effector thereagainst tourge left actuator sled (9752) toward the release position. In addition,a dowel hole (9806) opens downward and is positioned on upper right sledbody (9804). A dowel (9808) extends downward from right sled body (9804)and is positioned in longitudinal alignment with inner dowel hole(9806). In order to arrest movement of upper right actuator sled (9754)in the restraint and release positions, another distal cantilever catch(9796) laterally extends to the right from the distal portion of upperright sled body (9804), and another proximal cantilever catch (9796)laterally extends to the right from the proximal portion of upper rightsled body (9804). Again, distal and proximal cantilever catches (9796,9798) are respectively portions of distal and proximal detent couplings(9800, 9802) discussed below in greater detail.

FIG. 86 and FIGS. 95 and 96 show upper right and left actuator sleds(9752, 9754) as discussed above in detail as well as lower right andleft actuator sleds (9752, 9754). As briefly discussed above, thedescription of upper right and left actuator sleds (9752, 9754)similarly applies to lower right and left actuator sleds (9752, 9754)with like features having like numbers, but with reversed transversedirections (e.g. lower, upward, etc.). To this end, upper left actuatorsled (9752) and lower right actuator sled (9754) connect together asouter dowel (9808) snaps into outer dowel hole (9792) and inner dowel(9794) snaps into inner dowel hole (9806) with chassis (9736) positionedtherebetween. Upper right actuator sled (9754) and lower left actuatorsled (9752) similarly connect together as outer dowel (9808) snaps intoouter dowel hole (9792) and inner dowel (9794) snaps into inner dowelhole (9806) with chassis (9736) positioned therebetween. Each of innerand outer dowels (9794, 9808) extend through sled clearance holes (9770)to slidably connect left and right actuator sleds (9752, 9754) tochassis (9736).

FIG. 96 shows one example of a pair of distal arms (9755 a) and a pairof proximal arms (9755 b) respectively having platform (9730) positionedtherebetween and tracing opposing ramp surfaces (9782). A central plane(9810) is shown in FIG. 78 bisecting upper and lower portions ofbuttress applier cartridge (9716) through a central core of platform(9730). Distal arm (9755 a) has a distal retention surface (9812 a)transversely offset from central plane (9810) a relatively greaterdistance, and proximal arm (9755 b) has a proximal retention surface(9812 b) transversely offset from central plane (9810) a relativelylesser distance. Thereby, greater and lesser distances of distal andproximal retention surfaces (9812 a, 9812 b) trace ramp surfaces (9782)tapering from distal end (9780) of pad (9772) to proximal end (9778) ofpad (9772). Thus, distal and proximal retention surfaces (9812 a, 9812b) are offset in the transverse direction from each other and fromcentral plane (9810). In the present example, each of distal arm (9755a) and proximal arm (9755 b) are transversely spaced from the rampsurface (9782) an equal transverse dimension such that arms (9755 a,9755 b) equally trace ramp surfaces (9782) tapering from distal end(9780) of pad (9772) to proximal end (9778) of pad (9772).

As shown in FIGS. 97-99, left and right actuator sleds (9752, 9754) arerespectively urged outward from the restraint position to the releaseposition away from platform to disengage arms (9755 a, 9755 b) frombuttress assemblies (9712) on platform (9730) as discussed herein. Moreparticularly, distal and proximal detent couplings (9800, 9802)releasably connect left and right actuator sleds (9752, 9754) to chassis(9736) to arrest movement of left and right actuator sleds (9752, 9754)in the restraint position and the release position. Distal and proximaldetent couplings (9800, 9802) include distal and proximal cantilevercatches (9796, 9798) extending from each of left and right actuatorsleds (9752, 9754) as discussed briefly above. In addition, distal andproximal detent couplings (9800, 9802) respectively further includedistal and proximal ground cams (9814, 9816) extending from chassis(9736) in respective engagement with distal and proximal cantilevercatches (9796, 9798).

In the restraint position shown in FIG. 97, each distal cantilever catch(9796) is respectively engaged with each distal ground cam (9814), andeach proximal cantilever catch (9798) is respectively engaged with eachproximal ground cam (9816) to urge left and right actuator sleds (9752,9754) inward toward the restraint position. Directing left and rightactuator sleds (9752, 9754) outward from the restraint position towardthe release position as shown in FIG. 98 resiliently deflects distal andproximal cantilever catches (9796, 9798) as distal and proximalcantilever catches (9796, 9798) follow distal and proximal ground cams(9814, 9816). As distal and proximal cantilever catches (9796, 9798)pass around distal and proximal ground cams (9814, 9816), distal andproximal cantilever catches (9796, 9798) reach a tipping point wheredistal and proximal cantilever catches (9796, 9798) urge left and rightactuator sleds (9752, 9754) to the release position shown in FIG. 99. Inthe release position, each distal cantilever catch (9796) isrespectively engaged with each distal ground cam (9814), and eachproximal cantilever catch (9798) is respectively engaged with eachproximal ground cam (9816) to urge left and right actuator sleds (9752,9754) outward toward the release position. Thereby, distal and proximaldetent couplings (9800, 9802) effectively hold left and right actuatorsleds (9752, 9754) in the release position to inhibit arms (9755 a, 9755b) from inadvertently returning inward and catching buttress assembly(9712) upon removal of an end effector as discussed herein.

iii. Exemplary Adhesion of Buttress to Surgical Stapler and Cutting ofButtress Assembly with Tissue

As noted above, upper and lower buttress assemblies (9712) include upperand lower adhesive layers (9742) (or other form of adhesive material) toadhere respective buttresses (9714) to an underside of an anvil and deckof a staple cartridge of an end effector. Such adhesive may provideproper positioning of buttress (9714) before and during actuation of anend effector; then allow buttress (9714) to separate from the endeffector after the end effector has been actuated, without causingdamage to buttress (9714) that is substantial enough to compromise theproper subsequent functioning of buttress (9714). Buttress assemblies(9712) may further incorporate the teachings described in U.S. Pat. App.No. [ATTORNEY DOCKET NO. END8634USNP.0663974], entitled “AdhesiveDistribution on Buttress for Surgical Stapler,” filed on even dateherewith, the disclosure of which is hereby incorporated by reference.

By way of example only and not limitation, buttress applier cartridgeassembly (9710) can be used to apply buttress assemblies (9712) with endeffector (9040) as shown and described with respect to FIGS. 81-84. Insuch an instance, buttress assemblies (9712) are attached with endeffector (9040) in the same manner as described with buttress assemblies(9100, 9110). Moreover, other end effectors described herein can be usedin place of end effector (9040) such that buttress applier cartridgeassembly (9710) can be used to apply buttress assemblies (9712) with toany of those end effectors. As shown and described above, various endeffectors may have a straight configuration, a bent or curved tipconfiguration where the anvil includes a rigid bent or curved tip, or abent or curved tip configuration where the anvil includes a deformablebent or curve tip. Despite these different configurations, as will bedescribed further below, buttress applier cartridge assembly (9710) isconfigured for use with any such configuration end effector.Furthermore, as mentioned above, buttress applier cartridge assembly(9710) is configured to accommodate alternative camber orientations ofan end effector, including parallel-camber, over-camber, andunder-camber orientations. As mentioned above, pad (9772) providessufficient compression such that adhesive layers (9742) of buttresses(9714) completely or at least substantially contact the respect parts ofthe end effector along their longitudinal length to adhere buttresses(9712) to the end effector whether the end effector is configured withan over-camber orientation, under-camber orientation, or parallel-camberorientation.

iv. Exemplary Opening Feature Accommodating Curved Tip End Effectors

Referring to buttress applier cartridge (9716) as shown in FIGS. 85-99,another feature of buttress applier cartridge (9716) pertains to theability for buttress applier cartridge (9716) to be used with a varietyof end effectors, including those with a bent or curved tip, which couldbe as part of the anvil or even as part of the cartridge. In thisrespect, buttress applier cartridge (9716) comprises an opening (9701).Opening (9701) is configured as a space or void where a portion of anend effector can pass through buttress applier cartridge (9716) from atop side or upper side to a bottom side or lower side. As will bedescribed further below, when used with an end effector having a curvedtip, opening (9701) allows for the jaws of the end effector to be closedwith the curved tip passing through opening (9701) so that the upper jawand lower jaw of the end effector can close to at least the point wherethe upper jaw and lower jaw contact buttress assemblies (9712) along itsfull longitudinal length, or at least substantially along itslongitudinal length. At the same time, opening (9701) does not impede orhinder the use of straight tip design end effectors.

Referring now to FIGS. 85 and 95-99, in the present example opening(9701) is defined by chassis (9736) along a distal portion of opening(9701) and lateral sides of opening (9701). Furthermore, opening isdefined by platform (9730) along a proximal portion of opening (9701).Thus in the present example, multiple structures or components ofbuttress applier cartridge (9716) combine to define opening (9701). Insome other versions, opening (9701) may be defined by fewer, additional,or other components. Also in the present example, opening (9701) isdefined by chassis (9736) and platform (9730) such that opening (9701)comprises a U-shaped opening. In view of the teachings herein, otherways to define opening (9701) to provide for alternate opening shapeswill be apparent to those of ordinary skill in the art.

Referring to FIGS. 100 and 101, buttress applier cartridge assembly(9710) is shown used with end effector (9912). End effector (9912)comprises a straight tip configuration, similar to end effectors (9012,9040) described above. End effector (9912) comprises anvil (9918) andjaw (9916) holding a staple cartridge (9937). As shown in FIG. 100, whenend effector (9912) is positioned within buttress applier cartridgeassembly (9710) and closed, opening (9701) reveals a portion ofcartridge (9937) on the other side of platform (9730). This is the casein this example as end effector (9912) is configured such that cartridge(9937) extends further distally compared to anvil (9918) when endeffector (9912) is closed. As shown in FIG. 101, the view from the otherside in this configuration shows that opening (9701) is visually blockedby the distal portion of cartridge (9937). Nevertheless, buttressapplier cartridge assembly (9710) is configured for use with straighttipped end effectors such as end effectors (9012, 9040, 9912) describedherein, among others.

Referring to FIGS. 102 and 103, buttress applier cartridge assembly(9710) is shown used with end effector (1012). End effector (1012)comprises a bent or curved tip configuration, similar to end effectors(9212, 9312, 9412, 9512, 9612) described above. End effector (1012)comprises anvil (1018) and jaw (1016) holding a staple cartridge (1037).As shown in FIG. 102, when end effector (1012) is positioned withinbuttress applier cartridge assembly (9710) and closed, opening (9701)reveals a portion of cartridge (1037) on the other side of platform(9730). This is the case in this example as end effector (1012) isconfigured such that cartridge (1037) extends further distally comparedto anvil (9918) when end effector (9912) is closed and contactingplatform (9730). As shown in FIG. 103, with end effector (1012) closedand contacting platform (9730), a curved tip (1014) of anvil (1018)passes through opening (9701) extending toward cartridge (1037). In thepresent example, curved tip (1014) is rigid in some versions anddeformable in other versions. In either configuration for curved tip(1014), buttress applier cartridge assembly (9710) with opening (9701)accommodates anvil (1018) and curved tip (1014) such that curved tip(1014) extends through opening (9701) when loading buttress assemblies(9712) onto end effector (1012).

v. Exemplary Distal Alignment Feature for Opening Accommodating CurvedTip End Effectors

As mentioned above, opening (9701) is defined in part by chassis (9736)along a distal end of opening (9701) and lateral sides of opening(9701). In this manner, chassis (9736) comprises edge (9703) as seen inFIGS. 85 and 87 for example. Edge (9703) extends in a U-shaped manneralong a portion of a perimeter of opening (9701) thereby partiallydefining opening (9701).

Referring to FIG. 104, opening (9701) comprises alignment features(9705) that are configured to direct a curved tip of an end effector,such as curved tip (1014) of end effector (1012), into and throughopening (9701). In addition to directing the curved tip, alignmentfeatures (9705) assist in aligning the end effector relative to buttressapplier cartridge assembly (9710) so that buttress assemblies (9712) andend effector's jaws are aligned in a parallel or substantially parallelorientation with the end effector's jaws centered or substantiallycentered relative to buttress assemblies (9712). With this orientation,buttress assemblies (9712) can be adhered to the end effector such thatboth end effector and buttress assemblies (9712) share a commonlongitudinal axis.

As shown in FIG. 104, in one example, alignment features (9705) aredefined by edge (9703) of opening (9701). Alignment features (9705)comprise tapered surfaces that converge at a center of the thickness ofchassis (9736). Moreover, tapered surfaces of alignment features (9705)are oriented or sloped such that when a jaw of an end effector contactsthem, the jaw is directed toward the center of opening (9701). Asmentioned above, this directing and aligning action not only aligns thecurved tip of an end effector but promotes alignment of the end effectoras a whole relative to buttress applier cartridge assembly (9710).Furthermore, this alignment action promoted by alignment features (9705)occurs during the clamping of the end effector, as the curved tipextends further through opening (9701) when moving the end effector tothe closed position to clamp and contact platform (9730) to ultimatelyattach buttress assemblies (9712) with the end effector.

In some versions, opening (9701) is sized such that it is narrower thanthe maximum width of the curved tip of the end effector. By way ofexample, end effector (1012) has anvil (1018) with curved tip (1014).Curved tip (1014) gradually widens as it extends proximally as shown inFIG. 102. So in such an example, opening (9701) is narrower than thewidest portion of curved tip (1014). And when end effector (1012) isclosed and clamped on platform (9730), curved tip (1014) will contactedge (9703) of opening (9701). This in turn will cause alignmentfeatures (9705) to guide or direct curved tip (1014) and end effector(1012) into alignment with buttresses assemblies (9712) retained onplatform (9730) for adhering to end effector (1012). In view of theteachings herein, various sizes and configurations for opening (9701),edge (9703), and alignment features (9705) that can be used withbuttress applier cartridge assembly (9710) will be apparent to those ofordinary skill in the art.

Referring to FIGS. 105 and 106, another exemplary alignment feature(9707) is shown. Alignment feature (9707) is configured to connect withchassis (9736) as shown in FIG. 106. Alignment feature (9707) can beconfigured to be removable from and/or replaceable with chassis (9736).However, in other versions, alignment feature (9707) can be permanentlyattached with chassis (9736). In the present example, chassis (9736)comprises a pair of posts (9709) that are configured to engage a pair ofbores (9711) of alignment feature (9707). Chassis (9736) furthercomprises a pair of guides (9713) located proximally from posts (9709).Guides (9713) are each configured to receive end portions of one arm ofa pair of lateral arms (9715) of alignment feature (9707) as shown inFIG. 106.

In the present example, arms (9715) of alignment feature (9707) areconfigured to be resiliently biased and self-centering. In this manner,arms (9715) are configured to deflect outward as an end effector isclamped onto platform (9730). This deflection of arms (9715) allowsalignment feature (9707) to be used with end effectors having variationin size and curved tip geometry. Furthermore, with their resilient bias,arms (9715) are configured to guide the curved tip portion of an endeffector to a centered orientation relative to opening (9701). In someother versions, arms (9715) and alignment feature (9707) are sized for aspecific size or size range for end effectors such that arms (9715) maybe rigid and thus not be configured to deflect under clamping forces ofthe end effector, yet still provide guiding and centering of the endeffector by interaction of alignment feature (9707) with a curved tip ofthe end effector, as described further below.

Arms (9715) of alignment feature (9707) further comprise taperedsurfaces (9717) that are configured to contact and interact or engagewith a jaw of an end effector such that when a jaw of an end effectorcontacts them, the jaw is directed or guided toward the center ofopening (9701). This directing and aligning action of alignment feature(9707) not only aligns the curved tip of an end effector but promotesalignment of the end effector as a whole relative to buttress appliercartridge assembly (9710).

With opening (9701) and the curved tip end effector, the alignmentaction promoted by alignment feature (9707) occurs when clamping the endeffector, as the curved tip extends further through opening (9701). Byway of example, end effectors (9212, 9512, 9612) have respective anvils(9218, 9518, 9618) with curved tips that have tapered sides (9241, 9541,9641). When end effectors (9212, 9512, 9612), among others, are usedwith buttress applier cartridge assembly (9710), when clamping endeffectors (9212, 9512, 9612) onto platform (9730), tapered surfaces(9717) of alignment feature (9707) contact curved tips of end effectors(9212, 9512, 9612), and further contact tapered sides (9241, 9541, 9641)of end effectors (9212, 9512, 9612) as end effectors (9212, 9512, 9612)are clamped on platform (9730). This contact or engagement causesalignment feature (9707) to guide or direct the curved tips of endeffector (9212, 9512, 9612) such that end effectors (9212, 9512, 9612)are guided into alignment with buttresses assemblies (9712) retained onplatform (9730) for ultimately adhering to end effectors (9212, 9512,9612). In view of the teachings herein, other configurations for arms(9715) of alignment feature (9707) that can be used with buttressapplier cartridge assembly (9710) will be apparent to those of ordinaryskill in the art.

Referring to FIGS. 107 and 108, another exemplary alignment feature(9719) is shown as an anvil alignment rib. Alignment feature (9719) isconfigured to connect with chassis (9736) as shown in FIG. 107. In thepresent example, alignment feature (9719) is configured to be securedwith or formed with chassis (9736). However, in other versions,alignment feature (9719) can be selectively attached with chassis(9736). In the present example, alignment feature (9719) extendslaterally across opening (9701), with ends (9721, 9723) connecting tochassis (9736) on each side of opening (9701). Alignment feature (9719)further extends proximally to distally relative to opening (9701) with acenter portion (9725) being located most distally, and connecting withrespective side portions (9727, 9729). In this manner, alignment feature(9719) tapers as it extends proximally to distally. Furthermore, centerportion (9725) comprises curved portions (9731, 9733) that ultimatelyconnect with side portions (9727, 9729). With this configuration,alignment feature (9719) defines a non-linear decrease in spacing as itspans across opening (9701) and extends proximally to distally.

Alignment feature (9719) also comprises tapered surface (9735) thatextends along side portions (9727, 9729) and centered portion (9725). Inthis manner tapered surface (9735) of alignment feature (9719) extendsproximally to distally. Furthermore, tapered surface (9735) isconfigured to contact tapered sides of curved tip (1014) of an endeffector (1012) as end effector (1012) is clamped on platform (9730) asshown in FIGS. 107 and 108. This ultimately guides curved tip (1014) andend effector (1012) into centered alignment with opening (9701) andultimately with buttress assemblies (9712) retained on platform (9730).As mentioned above, the alignment and guiding of alignment feature(9719) operates in a similar fashion to other alignment featuresdescribed above where the clamping action of the end effector onplatform (9730) promotes contact or engagement of the curved tip of theend effector, and its tapered sides, with alignment feature (9719) andits tapered surface (9735) to center and align the end effector withretained buttress assemblies (9712) on platform (9730). In view of theabove description and examples of alignment features, otherconfigurations for one or more alignment features for use with buttressapplier cartridge assembly (9710) or other such buttress applicator willbe apparent to those of ordinary skill in the art.

XV. Exemplary Alternate Buttress Applier Cartridge with Distal Openingand Alignment Feature for Accommodating Curved Tip End Effectors

In other versions of a buttress applier cartridge, an alternate opening,similar to opening (9701) described above, can be incorporated into abuttress applier cartridge to accommodate an end effector having acurved tip. Referring to FIGS. 109-111, buttress applier cartridgeassembly (1110) is shown, which is similar to buttress applier cartridgeassembly (9710) shown and described above. To that extent, the teachingsabove with respect to buttress applier cartridge assembly (9710) applyequally to buttress applier cartridge assembly (1110) except for thefollowing differences described below.

Buttress applier cartridge assembly (1110) comprises buttress appliercartridge (1116) having housing assembly (9724), which has upper housing(9726) and lower housing (9728). Buttress applier cartridge (1116)further comprises chassis (1136) and platform (1130). In the presentexample, housing assembly (9724) defines a channel (1103) that isconfigured to accommodate an end effector, such as end effector (1012)as shown in FIGS. 110 and 111. As best seen in FIG. 109, platform (1130)is configured to retain buttress assemblies (9712) in the same manner asdescribed above with respect to buttress applier cartridge (9716). Inthe present example, platform (1130) extends proximally to distally suchthat the space or area defined by channel (1103) is encompassed byplatform (1130). Platform (1130) further includes opening (1101), whichis defined by a hole or cut-out in platform (1130). In this manner,opening (1101) is formed in platform (1130), and defined on all sides byplatform (1130). Similar to opening (9701) described above, opening(1101) is configured to allow curved tip (1014) of end effector (1012)or another similar end effector to pass through platform (1130) andchassis (1136). In this manner curved tip (1014) extends transverselyfrom one side of combined chassis (1136) and platform (1130) to theother side. Opening (1101) can be configured to be oversized relative tocurved tip (1014), undersized relative to curved tip (1014), or equal orsubstantially equal in size to curved tip (1014). In some cases,platform (1130) comprises a resilient material such that opening (1101)defined by platform (1130) is expandable, for instance when curved tip(1014) extends through opening (1101) and presses against sides ofopening (1101). In view of the teachings herein, other configurationsfor opening (1101) will be apparent to those of ordinary skill in theart.

In addition to opening (1101), similar to platform (9730), platform(1130) is configured to be thicker at its distal portion that isproximal to opening (1101) compared to the proximal portion of platform(1130). In this manner platform (1130) comprises a taper from its distalportion to its proximal portion. Platform (1130) in the present example,also includes a curb (1132) located at its proximal end. Curb (1132) isconfigured to prevent inadvertent or premature gripping of the jaws ofend effector (1012) with platform (1130) and buttress assemblies (9712)prior to end effector (1012) being intentionally clamped onto platform(1130). In other words, curb (1132) is configured to prevent prematuresubstantial contact of the first and second jaws of end effector (1012)with platform (9103) and buttress assemblies (9712) prior to clampingend effector (1012). As shown in FIG. 111, curb (1132) is compressiblelike platform (1130) such that when end effector (1012) is clamped, curb(1132) compresses and no longer prevents the jaws of end effector (1012)from gripping platform (1130) and thus picking up buttress assemblies(9712).

Referring to FIG. 109, channel (1103) includes a distal portion (9732)that is defined by lateral sides (9734). As shown, distal portion (9732)includes a taper proximally to distally as lateral sides (9734) convergeat the distal-most end of distal portion (9732). Accordingly, lateralsides (9734) are configured to guide curved tip (1014) of end effector(1012) toward a centerline of opening (1101) to align end effector(1012) with buttress assemblies (9712) retained on platform (1130). Asmentioned above, tapered surfaces may be included on lateral sides(9734) to further facilitate guiding curved tip (1014) of end effector(1012). In view of the teachings herein, additional or other alignmentfeatures other than lateral sides (9734) that may be incorporated intobuttress applier cartridge (1116) will be apparent to those of ordinaryskill in the art.

XVI. Exemplary Alternate Buttress Applier Cartridge for AccommodatingDeformable Curved Tip End Effectors

In other versions of a buttress applier cartridge, the buttress appliercartridge may be configured for use with curved tip end effectors, butwhere the curved tips are deformable. In such examples, while an openinglike opening (9701) or opening (1101) may be used, an opening may alsobe omitted. Referring to FIGS. 112-114, buttress applier cartridgeassembly (1210) is shown, which is similar to buttress applier cartridgeassembly (9710) shown and described above. To that extent, the teachingsabove with respect to buttress applier cartridge assembly (9710) applyequally to buttress applier cartridge assembly (1210) except for thefollowing differences described below.

Buttress applier cartridge assembly (1210) comprises buttress appliercartridge (1216) having housing assembly (9724), which has upper housing(9726) and lower housing (9728). Buttress applier cartridge (1216)further comprises chassis (1236) and platform (1230). In the presentexample, housing assembly (9724) defines a channel (1203) that isconfigured to accommodate an end effector, such as end effector (1312)as shown in FIGS. 112-114. As best seen in FIGS. 112 and 113, platform(1230) is configured to retain buttress assemblies (9712) in the samemanner as described above with respect to buttress applier cartridge(9716). In the present example, platform (1230) extends proximally todistally such that the space or area defined by channel (1203) isencompassed by platform (1230). In the present example platform (1230)is a continuous surface, or at least substantially continuous such thatcurved tip (1314) of end effector (1312) cannot pass through platform(1230). Platform (1230) comprises a proximal end portion (1278) and adistal end portion (1280). Extending further distally from distal endportion (1280), platform (1230) comprises contact portion (1282).Similar to platform (9730), platform (1230) is configured to becompressible and thicker at distal end portion (1280) than proximal endportion (1278). In this manner platform (1230) comprises a taper fromdistal end portion (1280) to proximal end portion (1278).

Referring to FIG. 112, end effector (1312) is shown within channel(1203) of buttress applier cartridge (1216), but in an unclamped or openstate. As shown, when curved tip (1314) touches contact portion (1282)without clamping force, curved tip (1314) does not deform and the jawsof end effector (1312) remain not contacting buttress assemblies (9712).Referring to FIG. 113, when end effector (1312) is clamped, withdeformable curved tip (1314), curved tip (1314) deforms so as to deflector straighten. This deformation occurs because curved tip (1314)contacts or touches contact portion (1282) of platform (1230) instead ofpassing through an opening as described above with other buttressapplier cartridges. The deformation of curved tip (1314) allowssufficient clamping action of end effector (1312) onto platform (1230)such that the jaws of end effector (1312) contact buttress assemblies(9712) so that buttress assemblies are applied to the jaws of endeffector (1312). As shown in the clamped state of FIG. 113, centerportion (1282) of platform (1230) in the present example is configuredto be deflectable. In this manner, contact portion (1282) is resilientso that it remains straight when not subjected to clamping forces fromend effector (1312). In other versions center portion (1282) may not bedeflectable. However, in some instances where contact portion (1282) isdeflectable, some degree of deflection of contact portion (1282) canreduce the stress on the connection of curved tip (1314) with theremainder of the anvil of end effector (1312).

Referring to FIG. 114, end effector (1312) is shown in the clamped statelike in FIG. 113. As shown, deformable curved tip (1314), in itsdeformed state, is slightly expanded in size outward relative to thewidth of the remainder of end effector (1312). Furthermore, an edge(1205) defining a distal end of channel (1203) of housing assembly(9724) is sized so that housing assembly (9724) is slightly larger thancurved tip (1314) in its deformed state when end effector (1312) isclamped. Accordingly, this provides sufficient clearance or space suchthat a full clamping of end effector (1312) onto platform (1230) can beachieved to transfer buttress assemblies (9712) to the jaws of endeffector (1312). In view of the teachings herein, other ways toconfigured buttress applier cartridge (1216) for use with deformablecurved tipped end effectors will be apparent to those of ordinary skillin the art.

XVII. Exemplary Alternate Buttress Applier Cartridge with ProximalAlignment Feature and Distal Opening to Accommodate Curved Tip EndEffectors

In other versions of a buttress applier cartridge, an alternate opening,similar to opening (9701) described above, can be incorporated into abuttress applier cartridge to accommodate an end effector having acurved tip. Additionally, those buttress applier cartridges describedherein can also include one or more alignment features configured toalign the end effector of the surgical stapler with the buttressassemblies prior to applying the buttress assemblies to the endeffector.

Referring to FIGS. 115-118, buttress applier cartridge assembly (2110)is shown, which is similar to buttress applier cartridge assembly (9710)shown and described above. To that extent, the teachings above withrespect to buttress applier cartridge assembly (9710) apply equally tobuttress applier cartridge assembly (2110) except for the differencesdescribed below. Buttress applier cartridge assembly (2110) comprisesbuttress applier cartridge (2116) having housing assembly (9724), whichhas upper housing (9726) and lower housing (9728). In the presentexample, housing assembly (9724) defines a channel (2103) that is openat a proximal end and configured to accommodate an end effector, such asend effector (1012) as shown in FIGS. 116 and 118.

Buttress applier cartridge (2116) further comprises chassis (2136) andplatform (2130). In some examples similar to the configuration forbuttress applier cartridge (9716) described above, chassis (2136) isconnectable with housing assembly (9724), and platform (2130) isconnectable with chassis (2136). In this manner platform (2130) isconnectable with housing assembly (9724) indirectly via chassis (2136).Still in other examples buttress applier cartridges (9716, 2116) can beconfigured such that platform (2136) may be directly connectable withhousing assembly (9724).

As best seen in FIG. 115, platform (2130) is configured to retainbuttress assemblies (9712) in the same manner as described above withrespect to buttress applier cartridge (9716). In the present example,platform (2130) is compressible and also extends proximally to distallysuch that the space or area defined by channel (2103) is encompassed byplatform (2130). Near a distal end of channel (2103), platform (2130)includes opening (2101), which is defined by a hole or cut-out inplatform (2130). With this configuration, opening (2101) is locateddistal to where one or more buttress assemblies (9712) are supported orsupportable by platform (2130). In the present example, opening (2101)comprises a U-shaped cut-out. In this manner, opening (2101) is formedin platform (2130), and defined on all sides by platform (2130). Similarto opening (9701) described above, opening (2101) is configured to allowcurved tip (1014) of end effector (1012) or another similar end effectorto pass through platform (2130) and/or chassis (2136). In this mannercurved tip (1014) extends transversely from one side of combined chassis(2136) and platform (2130) to the other side.

Opening (2101) can be configured to be oversized relative to curved tip(1014), undersized relative to curved tip (1014), or equal orsubstantially equal in size to curved tip (1014). In some cases, such aswith U-shaped opening (2101) described here and shown in FIG. 115,platform (2130) comprises a resilient material such that opening (2101)defined by platform (2130) is expandable, for instance when curved tip(1014) extends through opening (2101) and presses against sides ofopening (2101). Also in some cases, such as with U-shaped opening(2101), opening (2101) can be configured with a shape that resembles anoutline of the shape of curved tip (1014) of end effector (1012). Inthis way the shape of opening (2101) and curved tip (1014) of endeffector (1012) are complementary. In view of the teachings herein,other configurations for opening (2101) will be apparent to those ofordinary skill in the art.

Similar to platform (9730) described above, platform (2130) isconfigured to be thicker at a distal portion (2180) proximal to opening(2101) compared to a proximal portion (2178) of platform (2130). In thismanner platform (2130) comprises a taper from distal portion (2180) toproximal portion (2178). Stated another way, platform (2130) increasesin thickness from proximal portion (2178) to distal portion (2180). Asshown in the present example of FIG. 115, opening (2101) is locatedfurther distally on platform (2130) relative to distal portion (2180).Additionally in the present example, as shown in FIGS. 117 and 118, theportion of platform (2130) with opening (2101) is thinner relative todistal portion (2180).

Referring again to FIG. 116, in defining channel (2103), housingassembly (9724) comprises a V-shaped or U-shaped recess (2105) at thedistal end of channel (2103). In this manner, recess (2105) isconfigured to accommodate distal end or distal tip (1019) of curved tip(1014). Referring again to FIG. 115, in the present example, opening(2101) is located within the area defined by recess (2105). In thismanner, buttress applier cartridge (2116) is configured to accommodatecurved tip (1014) and distal end (1019) at least with features providedon housing assembly (9724) and platform (2130). In addition to providingspace to accommodate distal end (1019) of curved tip (1014) of endeffector (1012), in some instances recess (2105) may further assist inguiding or aligning end effector (1012) when clamping end effector(1012) onto platform (2130) such that end effector (1012) can pick-upbuttress assemblies (9712). However, as described below, other alignmentfeatures or structures can also be provided with buttress appliercartridge (2116) instead of, or in addition to, any alignment providedby recess (2105).

Referring to FIGS. 115, 117, and 118, buttress applier cartridge (2116)also includes an alignment feature (2132) located at a proximal end ofbuttress applier cartridge (2116). In the present example, alignmentfeature (2132) comprises a thin rigid portion that extends laterallyacross the width of channel (2103). In this fashion, alignment features(2132) extends orthogonally relative to the longitudinally extendingchannel (2103). When end effector (1012) is fully positioned withbuttress applier cartridge (2116) as shown in FIG. 117, alignmentfeature (2132) extends across the cut-line defined by a vertical slot ofthe end effector where a firing beam travels to sever clamped tissue,the same or similar to vertical slot (9049) and firing beam (9014) ofend effector (9012) described above. In some other versions, alignmentfeature (2132) may extend to a greater or lesser extent laterally acrossthe width of channel (2103) and the cut-line defined by the endeffector.

Alignment feature (2132) is configured as a proximal alignment feature.In this way, alignment feature (2132) is configured to engage or contacta proximal edge or one or more tissue stops of the end effector when theend effector is open prior to clamping but fully positioned withbuttress applier cartridge (2116) within channel (2103). In someinstances, the proximal edge or one or more tissue stops of the endeffector may be located on the jaw of the end effector comprising thestaple cartridge. In some other instances, the proximal edge or one ormore tissue stops of the end effector may be located on the jaw of theend effector comprising the anvil.

As shown in FIGS. 117 and 118, alignment feature (2132) is configured tocontact proximal edge (91016) of end effector (1012). In some cases,proximal edge (91016) is operable as a tissue stop such that proximaledge (91016) is prevents over inserting tissue within end effector(1012) to ensure a complete cutting and stapling of the target tissue.In other cases, one or more dedicated tissue stops extend from the endeffector, and in such cases alignment feature (2132) is configured tocontact such tissue stops. Referring to FIGS. 119 and 120, an endeffector (9912) is shown fully positioned with another buttress appliercartridge (2216), which is shown with housing assembly (9724) removed.Alignment feature (2132) is located at the proximal end and extendingfrom platform (2230). Alignment feature (2132) contacts tissue stop(9915) as best seen in FIG. 120.

Referring again to FIGS. 117 and 118, alignment feature (2132) isconnectable with platform (2130) and extends proximally from platform(2130). Furthermore, as shown in the present example, alignment feature(2132) is thinner than the adjacent part of platform (2130) from whichalignment feature (2132) extends. In this way, alignment feature (2132)is configured to not interfere with the end effector clamping ontoplatform (2130) to pick-up buttress assemblies (9712). Additionally asshown, alignment feature (2132) is positioned between where buttressassemblies (9712) are supported or supportable by platform (2130). Insome versions, alignment feature (2132) comprises a separate rigidstructure that connects with platform (2130). However, in otherversions, alignment feature (2132) may be a rigid proximal part or endof platform (2130) itself, such that alignment feature (2132) is formedas part of platform (2130).

When an end effector is used with a buttress applier cartridge havingalignment feature (2132), alignment feature (2132) guides the endeffector to align the end effector relative to the buttress assemblies(9712) supported by the buttress applier cartridge. Thus alignmentfeature (2132) is configured as a proximal alignment feature that alignsa longitudinal position of the end effector, including aligning thedistal part of the end effector.

In the illustrated example of FIGS. 116-118 where end effector (1012) isused with buttress applier cartridge assembly (2110), proximal edge(91016) is used to align longitudinal position of end effector (1012)relative to platform (2130) and buttress assemblies (9712) supportedthereon. Additionally, in the present example, alignment feature (2132)is configured to guide curved tip (1014) of end effector (1012) to aligncurved tip (1014) with opening (2101). In this way, buttress appliercartridge (2116) is configured so that the spacing between opening(2101) and alignment feature (2132) will allow for curved tip (1014) ofend effector (1012) to align with opening (2101) when proximal edge(91016) of end effector (1012) contacts alignment feature (2132) priorto clamping end effector (1012) on platform (2130). Furthermore, whensubsequently clamping end effector (1012), the alignment of curved tip(1014) with opening (2101) allows at least a portion of curved tip(1014) to extend through or pass through opening (2101). As shown inFIG. 118, when this occurs, opening (2101) deforms such that the portionof platform (2130) around opening (2101) deflects downward away fromcurved tip (1014) as curved tip (1014) contacts platform (2130) andpushes platform (2130) downward. In view of the teachings herein, otherways to incorporate one or more alignment features with a buttressapplier cartridge that align an end effector of a surgical stapler withthe buttress applier cartridge, or ways to modify alignment feature(2132) for use with such an end effector will be apparent to those ofordinary skill in the art.

XVIII. Exemplary Alternate Buttress Applier Cartridge with PlatformPocket Feature to Accommodate Curved Tip End Effectors

In other versions of a buttress applier cartridge, instead of a hole oropening, similar to opening (9701) described above, a pocket feature canbe incorporated into the platform of a buttress applier cartridge toaccommodate an end effector having a curved tip. By way of example onlyand not limitation, several versions of such pocket features are shownand described herein. Furthermore, in view of the teachings herein,other configurations for such pocket features will be apparent to thoseof ordinary skill in the art.

A. Exemplary Distal Platform U-Shaped Slit

Referring to FIGS. 121-123, buttress applier cartridge assembly (4110)is shown, which is similar to buttress applier cartridge assembly (9710)shown and described above. To that extent, the teachings above withrespect to buttress applier cartridge assembly (9710) apply equally tobuttress applier cartridge assembly (4110) except for the followingdifferences described below.

Buttress applier cartridge assembly (4110) comprises buttress appliercartridge (4116) having housing assembly (9724), which has upper housing(9726) and lower housing (9728). Buttress applier cartridge (4116)further comprises chassis (9736) and platform (4130). In the presentexample, housing assembly (9724) defines a channel (4103) that isconfigured to accommodate an end effector, such as end effector (1012)as shown in FIGS. 122 and 123. Platform (4130) is configured to retainbuttress assemblies (9712) in the same manner as described above withrespect to buttress applier cartridge (9716). In the present example,platform (4130) extends proximally to distally such that the space orarea defined by channel (4103) is encompassed by platform (4130).

Buttress applier cartridge (4116) further includes pocket feature(4100). In the present example, pocket feature (4100) is located distalto where platform (4130) supports buttress assemblies (9712). As shownin FIGS. 122 and 123, pocket feature (4100) is also transverselypositioned between where buttress assemblies (9712) are supported onplatform (4130). With this positioning, pocket feature (4100) isconfigured to receive a curved tip of an end effector when clamping theend effector onto platform (4130) as described further below.

In the present example, pocket feature (4100) comprises a slit (4101)formed in platform (4130). Slit (4101) comprises a U-shape in thepresent example. Similar to opening (9701) described above, slit (4101)is configured to allow curved tip (1014) of end effector (1012) oranother similar end effector to pass through platform (4130) and/orchassis (9736). In this manner curved tip (1014) extends transverselyfrom one side of combined chassis (9736) and platform (4130) to theother side. Also, slit (4101) is configured to deform when curved tip(1014) of end effector (1012) passes through pocket feature (4100).

Slit (4101) can be configured to be oversized relative to curved tip(1014), undersized relative to curved tip (1014), or equal orsubstantially equal in size to curved tip (1014). In some cases,platform (4130) comprises a resilient material such that slit (4101)defined by platform (4130) is expandable, for instance when curved tip(1014) extends through pocket feature (4100) and presses against sidesof slit (4101). Also in some cases, slit (4101) can be configured with ashape that resembles an outline of the shape of curved tip (1014) of endeffector (1012). In this way the shape of slit (4101) and curved tip(1014) of end effector (1012) are complementary. Additionally, housingassembly (9724) may also comprise a distal portion (9732) of channel(4103) that has a shape that complements curved tip (1014) of endeffector (1012) thereby accommodating placement and or guiding curvedtip (1014) to slit (4101).

Similar to platform (9730), platform (4130) is configured to becompressible and thicker at a distal portion (4180) that is proximal toslit (4101) compared to a proximal portion (4178) of platform (4130). Inthis manner platform (4130) comprises a taper from distal portion (4180)to proximal portion (4178). This thickness profile or configuration forplatform (4130) compensates for any jaw deflection of the end effectorwhen clamping on platform (4130) to pick-up buttress assemblies (9712).Platform (4130) in the present example, may also include one or morealignment features such as those described in U.S. Pat. App. No.[ATTORNEY DOCKET NO. END9073USNP1.0714572], entitled “Curved TipSurgical Stapler Buttress Assembly Applicator with Proximal AlignmentFeatures,” filed on even date herewith; U.S. Pat. App. No. [ATTORNEYDOCKET NO. END9072USNP1.0714574], entitled “Curved Tip Surgical StaplerButtress Assembly Applicator with Opening Feature for Curved TipAlignment,” filed on even date herewith, the disclosures of which arehereby incorporated by reference. Additionally, platform (4130) mayinstead or in addition include one or more features to prevent prematureclamping and/or contact of the end effector with the buttress assembliesretained on platform (4130). Examples of such features are described inU.S. Pat. App. No. [ATTORNEY DOCKET NO. END9072USNP1.0714574], entitled“Curved Tip Surgical Stapler Buttress Assembly Applicator with OpeningFeature for Curved Tip Alignment,” filed on even date herewith, thedisclosure of which is hereby incorporated by reference.

With pocket feature (4100) formed in platform (4130), pocket feature(4100) defines or provides a region (4102) of platform (4130) thatcomprises a reduced stiffness. Region (4102) is located on and aroundplatform (4130) where pocket feature (4100) is positioned. The reducedstiffness of region (4102) promotes deflection and/or deformation ofplatform (4130) when region (4102) is contacted by curved tip (1014) ofend effector (1012) when clamping end effector (1012) on platform(4130).

Still referring to FIGS. 121-123, U-shaped slit (4101) defines a flap(4104) of platform (4130). Furthermore, slit (4101) is continuous in thepresent example such that flap (4104) is configured to deflect away fromthe remainder of platform (4130) when contacted by curved tip (1014) ofend effector (1012) when clamping end effector (1012) to platform(4130). With the shape of slit (4101) being U-shaped in the presentexample, flap (4104) also has a U-shape.

As mentioned above, buttress applier cartridge assembly (4110) includesthose features described above with respect to buttress appliercartridge assembly (9710) except for the differences described herein.To this extent, buttress cartridge (4116) comprises actuator sleds(9752, 9754) as shown in FIGS. 86 and 91-94. In the present example,actuator sleds (9752, 9754), which may also be referred to herein asmovable sleds (9752, 9754), connect with chassis (9736) in the samemanner that actuator sleds (9752, 9754) connect with chassis (9736) asdescribed above. As shown in FIG. 86, actuator sleds (9752, 9754)comprise a first set of actuator sleds (9752, 9754) located orpositioned above platform (9736), and a second set of actuator sleds(9752, 9754) located or positioned below platform (9736). Actuator sleds(9752, 9754) each comprise a pair of arms (9755 a, 9755 b) configuredfor contact by end effector (1012). This contact drives or pushesactuator sleds (9752, 9754) laterally, which causes arms (9755 a, 9755b) to disengage with buttress assemblies (9712) such that buttressassemblies (9712) can be applied to the jaws of end effector (1012).

Referring to the clamping sequence as shown in FIGS. 122 and 123, withpocket feature (4100) of platform (4130), when end effector (1012) isopen or not clamped and positioned within channel (4103) of buttressapplier cartridge (4116), jaw (1016) of end effector (1012) ispositioned close and adjacent to platform (4130), and in a substantiallyparallel orientation relative to platform (4130). Furthermore, both thedistal end of jaw (1016) and the proximal end of jaw (1016) are evenlyor substantially evenly spaced from platform (4130). As shown in FIG.122, with this arrangement, jaw (1016) is positioned to makesubstantially simultaneous contact with arms (9755 a, 9755 b) ofactuator sleds (9752, 9754) located adjacent to jaw (1016).

At the same time, on the opposite side where anvil (1018) is located, inthe positioned but open and not clamped state, anvil (1018) ispositioned angled relative to platform (4130). In this fashion, theproximal end of anvil (1018) is positioned closer to platform (4130)while the distal end of anvil (1018) is positioned further from platform(4130). Again as shown in FIG. 122, with this arrangement, anvil (1018)is positioned such that the proximal end of anvil (1018) will makecontact with arms (9755 a, 9755 b) of actuator sleds (9752, 9754)located adjacent to anvil (1018) first, and thereafter the distal end ofanvil (1018) will make contact with arms (9755 a, 9755 b) of actuatorsleds (9752, 9754) located adjacent to anvil (1018).

With this configuration, and as shown and understood from the clampingsequence of FIGS. 122 and 123, during positioning and clamping endeffector (1012) on platform (4130), the lateral movement of the firstset of actuator sleds (9752, 9754) located along the side of platform(4130) adjacent to anvil (1018) differs from the lateral movement of thesecond set of actuator sleds (9752, 9754) located along the side ofplatform (4130) adjacent to jaw (1016). For instance, in the presentexample, clamping end effector (1012) will first fully release buttressassembly (9712) being retained by the second set of actuator sleds(9752, 9754) adjacent jaw (1016), and thereafter fully release buttressassembly (9712) being retained by the first set of actuator sleds (9752,9754) adjacent anvil (1018). While the above examples illustrate anddescribe differing lateral movement for actuator sleds (9752, 9754)depending on their position relative to end effector (1012) whenclamping, in other versions buttress applier cartridge (4116) can beconfigured in other ways such that the lateral movement of actuatorsleds (9752, 9754) and the release timing of buttress assemblies (9712)for application to end effector (1012) may differ in other ways, or maybe substantially the same.

B. Exemplary Distal Platform Perforated Slit

Referring now to FIG. 124, a distal portion of buttress appliercartridge assembly (55110) is shown, which is similar to buttressapplier cartridge assemblies (9710, 4110) shown and described above. Tothat extent, the teachings above with respect to buttress appliercartridge assemblies (9710, 4110) apply equally to buttress appliercartridge assembly (55110) except for the following differencesdescribed below.

Buttress applier cartridge assembly (55110) comprises buttress appliercartridge (55116) having housing assembly (9724), chassis (9736), andplatform (55130). In the present example, housing assembly (9724)defines a channel (55103) that is configured to accommodate an endeffector, such as end effector (1012) as shown in FIGS. 122 and 123.Platform (55130) is configured to retain buttress assemblies (9712) inthe same manner as described above with respect to buttress appliercartridges (9716, 4116). In the present example, platform (55130)extends proximally to distally such that the space or area defined bychannel (55103) is encompassed by platform (55130).

Buttress applier cartridge (55116) further includes pocket feature(55100). In the present example, pocket feature (55100) is locateddistal to where platform (55130) supports buttress assemblies (9712).Pocket feature (55100) is also transversely positioned between wherebuttress assemblies (9712) are supported on platform (55130). With thispositioning, pocket feature (55100) is configured to receive a curvedtip of an end effector when clamping the end effector onto platform(55130) as described further below.

In the present example, pocket feature (55100) comprises a perforatedslit (55101) formed in platform (55130). Slit (55101) is configured toallow curved tip (1014) of end effector (1012) or another similar endeffector to deflect platform (55130) when clamping force is applied toend effector (1012). Also, slit (55101) is configured to deform whencurved tip (1014) of end effector (1012) press against pocket feature(55100).

Slit (55101) can be configured to be oversized relative to curved tip(1014), undersized relative to curved tip (1014), or equal orsubstantially equal in size to curved tip (1014). In some cases,platform (55130) comprises a resilient material such that slit (55101)defined by platform (55130) is expandable, for instance when curved tip(1014) contacts and presses against pocket feature (55100). In thepresent example, perforated slit (55101) extends longitudinally andalong a central axis of buttress applier cartridge (55116). However, insome cases, perforated slit (55101) can be configured with a shape thatresembles an outline of the shape of curved tip (1014) of end effector(1012). In this way the shape of slit (55101) and curved tip (1014) ofend effector (1012) are complementary. Additionally, housing assembly(9724) may also comprise a distal portion (9732) of channel (55103) thathas a shape that complements curved tip (1014) of end effector (1012)thereby accommodating placement and or guiding curved tip (1014) to slit(55101).

Similar to platform (9730), platform (55130) is configured to becompressible and thicker at its distal portion that is proximal to slit(55101) compared to its proximal portion. In this manner platform(55130) comprises a taper from its distal portion to its proximalportion. This thickness profile or configuration for platform (55130)compensates for any jaw deflection of the end effector when clamping onplatform (55130) to pick-up buttress assemblies (9712). Platform (55130)in the present example, may also include one or more alignment featuressuch as those described in U.S. Pat. App. No. [ATTORNEY DOCKET NO.END9073USNP1.0714572], entitled “Curved Tip Surgical Stapler ButtressAssembly Applicator with Proximal Alignment Features,” filed on evendate herewith; U.S. Pat. App. No. [ATTORNEY DOCKET NO.END9072USNP1.0714574], entitled “Curved Tip Surgical Stapler ButtressAssembly Applicator with Opening Feature for Curved Tip Alignment,”filed on even date herewith, the disclosures of which are herebyincorporated by reference. Additionally, platform (55130) may instead orin addition include one or more features to prevent premature clampingand/or contact of the end effector with the buttress assemblies retainedon platform (4130). Examples of such features are described in U.S. Pat.App. No. [ATTORNEY DOCKET NO. END9072USNP1.0714574], entitled “CurvedTip Surgical Stapler Buttress Assembly Applicator with Opening Featurefor Curved Tip Alignment,” filed on even date herewith, the disclosureof which is hereby incorporated by reference.

With pocket feature (55100) formed in platform (55130), pocket feature(55100) defines or provides a region (55102) of platform (55130) thatcomprises a reduced stiffness. Region (55102) is located on and aroundplatform (55130) where pocket feature (55100) is positioned. The reducedstiffness of region (55102) promotes deflection and/or deformation ofplatform (55130) when region (55102) is contacted by curved tip (1014)of end effector (1012) when clamping end effector (1012) on platform(55130).

As mentioned above, buttress applier cartridge assembly (55110) includesthose features described above with respect to buttress appliercartridge assemblies (9710, 4110) except for the differences describedherein. To this extent, the description of actuator sleds (9752, 9754)above as it pertains to buttress applier cartridge (4116) appliesequally here to buttress applier cartridge (55116).

C. Exemplary Distal Platform T-Shaped Slit

Referring to FIG. 125, buttress applier cartridge assembly (6110) isshown, which is similar to buttress applier cartridge assemblies (9710,4110) shown and described above. To that extent, the teachings abovewith respect to buttress applier cartridge assemblies (9710, 4110) applyequally to buttress applier cartridge assembly (6110) except for thefollowing differences described below.

Buttress applier cartridge assembly (6110) comprises buttress appliercartridge (6116) having housing assembly (9724), chassis (9736), andplatform (6130). In the present example, housing assembly (9724) definesa channel (6103) that is configured to accommodate an end effector, suchas end effector (1012) as shown in FIGS. 122 and 123. Platform (6130) isconfigured to retain buttress assemblies (9712) in the same manner asdescribed above with respect to buttress applier cartridge (9716). Inthe present example, platform (6130) extends proximally to distally suchthat the space or area defined by channel (6103) is encompassed byplatform (6130).

Buttress applier cartridge (6116) further includes pocket feature(6100). In the present example, pocket feature (6100) is located distalto where platform (6130) supports buttress assemblies (9712). Pocketfeature (6100) is also transversely positioned between where buttressassemblies (9712) are supported on platform (6130). With thispositioning, pocket feature (6100) is configured to receive a curved tipof an end effector when clamping the end effector onto platform (6130)as described further below.

In the present example, pocket feature (6100) comprises a slit (6101)formed in platform (6130). Slit (6101) comprises a T-shape in thepresent example. Similar to opening (9701) described above, slit (6101)is configured to allow curved tip (1014) of end effector (1012) oranother similar end effector to pass through platform (6130) and/orchassis (9736). In this manner curved tip (1014) extends transverselyfrom one side of combined chassis (9736) and platform (6130) to theother side. Also, slit (6101) is configured to deform when curved tip(1014) of end effector (1012) passes through pocket feature (6100).

Slit (6101) can be configured to be oversized relative to curved tip(1014), undersized relative to curved tip (1014), or equal orsubstantially equal in size to curved tip (1014). In some cases,platform (6130) comprises a resilient material such that slit (6101)defined by platform (6130) is expandable, for instance when curved tip(1014) extends through pocket feature (6100) and presses against sidesof slit (6101). Also in some cases, slit (6101) can be configured with ashape that resembles an outline of the shape of curved tip (1014) of endeffector (1012). In this way the shape of slit (6101) and curved tip(1014) of end effector (1012) are complementary. Additionally, housingassembly (9724) may also comprise a distal portion (9732) of channel(6103) that has a shape that complements curved tip (1014) of endeffector (1012) thereby accommodating placement and or guiding curvedtip (1014) to slit (6101).

Similar to platform (9730), platform (6130) is configured to becompressible and thicker at its distal portion that is proximal to slit(6101) compared to its proximal portion. In this manner platform (6130)comprises a taper from its distal portion to its proximal portion. Thisthickness profile or configuration for platform (6130) compensates forany jaw deflection of the end effector when clamping on platform (6130)to pick-up buttress assemblies (9712). Platform (6130) in the presentexample, may also include one or more alignment features such as thosedescribed in U.S. Pat. App. No. [ATTORNEY DOCKET NO.END9073USNP1.0714572], entitled “Curved Tip Surgical Stapler ButtressAssembly Applicator with Proximal Alignment Features,” filed on evendate herewith; U.S. Pat. App. No. [ATTORNEY DOCKET NO.END9072USNP1.0714574], entitled “Curved Tip Surgical Stapler ButtressAssembly Applicator with Opening Feature for Curved Tip Alignment,”filed on even date herewith, the disclosures of which are herebyincorporated by reference. Additionally, platform (6130) may instead orin addition include one or more features to prevent premature clampingand/or contact of the end effector with the buttress assemblies retainedon platform (4130). Examples of such features are described in U.S. Pat.App. No. [ATTORNEY DOCKET NO. END9072USNP1.0714574], entitled “CurvedTip Surgical Stapler Buttress Assembly Applicator with Opening Featurefor Curved Tip Alignment,” filed on even date herewith, the disclosureof which is hereby incorporated by reference.

With pocket feature (6100) formed in platform (6130), pocket feature(6100) defines or provides a region (6102) of platform (6130) thatcomprises a reduced stiffness. Region (6102) is located on and aroundplatform (6130) where pocket feature (6100) is positioned. The reducedstiffness of region (6102) promotes deflection and/or deformation ofplatform (6130) when region (6102) is contacted by curved tip (1014) ofend effector (1012) when clamping end effector (1012) on platform(6130).

Still referring to FIG. 125, T-shaped slit (6101) defines a pair offlaps (6104, 6105) of platform (6130). Furthermore, slit (6101) iscontinuous in the present example such that flaps (6104, 6105) areconfigured to deflect away from the remainder of platform (6130) whencontacted by curved tip (1014) of end effector (1012) when clamping endeffector (1012) to platform (6130). With the shape of slit (6101) beingT-shaped in the present example, flaps (6104, 6105) each comprise atriangular shape.

As mentioned above, buttress applier cartridge assembly (6110) includesthose features described above with respect to buttress appliercartridge assemblies (9710, 4110) except for the differences describedherein. To this extent, the description of actuator sleds (9752, 9754)above as it pertains to buttress applier cartridge (4116) appliesequally here to buttress applier cartridge (6116).

D. Exemplary Platform Profile

FIG. 126 illustrates an exemplary version of platforms (4130, 55130,6130) used with respective buttress applier cartridges (4116, 55116,6116). In particular, FIG. 126 shows a cross-section view, with buttressassemblies (9712) removed, to illustrate a lateral profile of platforms(4130, 55130, 6130). In this example, platforms (4130, 55130, 6130)define a longitudinally extending central region (3500). Central region(3500) defines a central axis (CA) that extends longitudinally alongcentral region (3500) of platforms (4130, 55130, 6130) as indicated inFIG. 121 with reference to platform (4130). As shown in FIG. 126,platforms (4130, 55130, 6130) comprise a smaller thickness along centralaxis (CA) of central region (3500) compared to the thickness ofplatforms (4130, 55130, 6130) adjacent to central region (3500).

In addition to central region (3500), platforms (4130, 55130, 6130)further comprise a pair of longitudinally extending outer regions(3501). As shown in FIG. 126, one of outer regions (3501) is located oneach side of central region (3500). With this configuration, and asshown in the illustrated version, the thickness of platforms (4130,55130, 6130) increases as platforms (4130, 55130, 6130) extend laterallyfrom central region (3500) to outer regions (3501). Furthermore, thisthickness increase is progressive, showing a gradual increase inthickness the further outward from central region (3500) platforms(4130, 55130, 6130) extends up until at least reaching housing assembly(9724) defining channels (4103, 55103, 6103).

With the above the lateral profile of platforms (4130, 55130, 6130),platforms (4130, 55130, 6130) are configured to accommodate endeffectors that may include a portion of a cutting member, such as atranslatable knife or firing beam, that extends distally at least someamount such that the cutting member would be positioned over a part ofplatforms (4130, 55130, 6130) when the end effector is clamped onplatforms (4130, 55130, 6130) to pick-up buttress assemblies (9712). Inview of the teachings herein, other ways to configure platforms (4130,55130, 6130) to accommodate various end effectors having various tipconfigurations including curved tips or having various internalstructures such as protruding cutting members or low-height cartridges,etc. will be apparent to those of ordinary skill in the art.

The various buttress applier cartridges described herein may be usedwith any of the end effectors described herein. By way of example, andnot limitation, those features of the buttress applier cartridges thatare configured to work with and/or accommodate an end effector having acurved tip make the buttress applier cartridges suitable for use withend effectors having various styles and configurations for the curvedtip. For instance, the buttress applier cartridges described herein withfeatures for a curved tip end effector can be used with end effectorswhere the curved tip may be gradually curved, or where the curved tipmay be non-aligned or at an angle relative to the axis of the anvil suchthat the curved tip has a more angled or bent configuration rather thangradual curve. Also, the buttress applier cartridges with features toaccommodate end effectors with a curved tip described herein can be usedwith, or configured for use with, end effectors where the curved tipportion is spaced from the distal end of the cartridge or terminates atthe same or similar point as the distal end of the cartridge. Also, thebuttress applier cartridges with features to accommodate end effectorswith a curved tip described herein can be used, or configured for usewith, end effectors that have curved tips configured for different usesor applications such as atraumatic tips, dissecting tips, visualizationtips, placement tips, deflectable or deformable tips, and combinationsthereof, etc. In view of the teachings herein, other ways to configurethe buttress applier cartridges described herein to work with the endeffectors described herein will be apparent to those of ordinary skillin the art.

XIX. Exemplary Combinations

The following examples relate to various non-exhaustive ways in whichthe teachings herein may be combined or applied. It should be understoodthat the following examples are not intended to restrict the coverage ofany claims that may be presented at any time in this application or insubsequent filings of this application No disclaimer is intended. Thefollowing examples are being provided for nothing more than merelyillustrative purposes. It is contemplated that the various teachingsherein may be arranged and applied in numerous other ways. It is alsocontemplated that some variations may omit certain features referred toin the below examples. Therefore, none of the aspects or featuresreferred to below should be deemed critical unless otherwise explicitlyindicated as such at a later date by the inventors or by a successor ininterest to the inventors. If any claims are presented in thisapplication or in subsequent filings related to this application thatinclude additional features beyond those referred to below, thoseadditional features shall not be presumed to have been added for anyreason relating to patentability.

Example 1

A buttress assembly for reinforcing tissue layers joined by surgicalstapling, comprises (a) a buttress comprising a first surface and asecond surface, wherein the buttress further comprises a proximal endand a distal end. The buttress defines a longitudinal axis extendingbetween the proximal end and the distal end, wherein the buttressfurther comprises a center region adjacent to a first edge region on oneside of the center region and adjacent to a second edge region on theother side of the center region. The buttress assembly also comprises(b) an adhesive applied to a select one of the first surface and thesecond surface of the buttress, wherein the adhesive extendscontinuously from the proximal end of the buttress to the distal end ofthe buttress. The adhesive is located along the first edge region andthe second edge region leaving the center region of the buttresssubstantially free of the adhesive.

Example 2

The buttress assembly of Example 1, wherein the center region of thebuttress comprises one or more slits configured to promote separation ofthe buttress into halves.

Example 3

The buttress assembly of any one or more of Examples 1 through 2,wherein the adhesive comprises an uneven distribution that comprisesmore of the adhesive at the distal end of the buttress than at theproximal end of the buttress.

Example 4

The buttress assembly of any one or more of Examples 1 through 3,wherein the adhesive comprises a first bead of the adhesive extendingfrom the proximal end of the buttress to the distal end of the buttress,and wherein the adhesive further comprises a second bead of the adhesiveextending from the proximal end of the buttress to the distal end of thebuttress.

Example 5

The buttress assembly of Example 4, wherein the first bead of theadhesive partially overlaps the second bead of the adhesive along atleast a portion of a length of the buttress.

Example 6

The buttress assembly of any one or more of Examples 4 through 5,wherein the first bead of the adhesive is spaced apart from the secondbead of the adhesive along at least a portion of the length of thebuttress.

Example 7

The buttress assembly of any one or more of Examples 4 through 6,wherein the second bead of the adhesive extends further proximally thanthe first bead of the adhesive.

Example 8

The buttress assembly of any one or more of Examples 4 through 7,wherein the first bead of the adhesive and the second bead of theadhesive extend distally to substantially the same extent relative tothe buttress.

Example 9

The buttress assembly of any one or more of Examples 4 through 8,wherein the adhesive comprises a third bead of the adhesive extendingfrom the proximal end of the buttress to the distal end of the buttress,and wherein the adhesive further comprises a fourth bead of the adhesiveextending from the proximal end of the buttress to the distal end of thebuttress.

Example 10

The buttress assembly of any one or more of Examples 4 through 9,wherein the first and the second beads of the adhesive are collectivelysymmetrical with the third and the fourth beads of the adhesive aboutthe longitudinal axis of the buttress that defines a centerline of thebuttress.

Example 11

The buttress assembly of any one or more of Examples 1 through 10,wherein the adhesive comprises a minimum height such that where theadhesive is applied to the buttress the adhesive sits proud of thebuttress.

Example 12

The buttress assembly of Example 11, wherein the minimum height of theadhesive is between about 0.254 mm and about 1.27 mm.

Example 13

The buttress assembly of any one or more of Examples 11 through 12,wherein the minimum height of the adhesive is between about 0.4064 mmand about 0.762 mm.

Example 14

The buttress assembly of any one or more of Examples 11 through 13,wherein the minimum height of the adhesive is configured tosubstantially match a depth of a staple forming pocket of an anvil of anend effector of a surgical stapler.

Example 15

The buttress assembly of any one or more of Examples 11 through 14,wherein the minimum height of the adhesive is configured tosubstantially match a height of a pocket extender of a staple cartridgeof an end effector of a surgical stapler.

Example 16

A buttress assembly for reinforcing tissue layers joined by surgicalstapling, comprises (a) a buttress comprising a first surface and asecond surface, wherein the buttress further comprises a proximal endand a distal end. The buttress defines a length from the proximal end tothe distal end, wherein the buttress defines a longitudinal axisextending between the proximal end and the distal end. The buttressfurther comprises a center region adjacent to a first edge region on oneside of the center region and adjacent to a second edge region on theother side of the center region, wherein the buttress is configured tobe cut into substantially equal halves by cutting through the centerregion. The buttress assembly also comprises (b) an adhesive applied toa select one of the first surface and the second surface of thebuttress, wherein the adhesive extends from the proximal end of thebuttress to the distal end of the buttress. The adhesive is locatedalong the first edge region and the second edge region leaving thecenter region of the buttress substantially free of the adhesive,wherein the adhesive comprises an asymmetric distribution along thelength of the buttress.

Example 17

The buttress assembly of Example 16, wherein the adhesive on the firstedge region and the second edge region changes between areas of greateradhesive and areas of lesser adhesive along the length of the buttress,wherein the areas of greater adhesive on the first edge region arelocated opposite to the areas of lesser adhesive on the second edgeregion, and wherein the areas of greater adhesive on the second edgeregion are located opposite to the areas of lesser adhesive on the firstedge region.

Example 18

The buttress assembly of any one or more of Examples 16 through 17,wherein the asymmetric distribution of the adhesive is configured toreduce the force needed for releasing the buttress assembly from aselect one of an anvil and a staple cartridge of an end effector of asurgical stapler when opening the end effector.

Example 19

An apparatus for reinforcing tissue layers joined by surgical stapling,comprises (a) a pair of buttress assemblies, each buttress assembly ofthe pair comprising (i) a buttress comprising a first surface and asecond surface, wherein the buttress further comprises a proximal endand a distal end, wherein the buttress defines a length from theproximal end to the distal end, wherein the buttress further comprises acenter region adjacent to a first edge region on one side of the centerregion and adjacent to a second edge region on the other side of thecenter region, wherein the buttress is configured to be cut intosubstantially equal halves by cutting through the center region, and(ii) an adhesive applied to a select one of the first surface and thesecond surface of the buttress, wherein the adhesive extends from theproximal end of the buttress to the distal end of the buttress, whereinthe adhesive is located along the first edge region and the second edgeregion leaving the center region of the buttress substantially free ofthe adhesive, wherein the adhesive comprises an asymmetric distributionalong the length of the buttress having the adhesive on the first edgeregion and the second edge region changing between areas of greateradhesive and areas of lesser adhesive, wherein the areas of greateradhesive on the first edge region are located opposite to the areas oflesser adhesive on the second edge region, and wherein the areas ofgreater adhesive on the second edge region are located opposite to theareas of lesser adhesive on the first edge region. The apparatus alsocomprises (b) each of the buttress assemblies are configured to bepositioned in an opposing manner with the adhesive of one of thebuttress assemblies facing away from the adhesive of the other of thebuttress assemblies, wherein when positioned in the opposing manner, theareas of greater adhesive on one of the buttress assemblies are alignedwith the areas of lesser adhesive on the other of the buttressassemblies.

Example 20

The apparatus of Example 19, wherein the center region of the buttresscomprises one or more slits configured to promote cutting the buttressinto halves.

Example 21

A buttress assembly, for reinforcing tissue layers joined by surgicalstapling, comprises (a) a multi-layer base material comprising (i) amesh layer comprising a first mesh surface and a second mesh surface,wherein the first mesh surface is configured to contact the tissuejoined by the surgical stapling, (ii) a first film layer contacting thesecond mesh surface of the mesh layer, wherein the first film layer isconfigured as an adhesive layer, and (iii) a second film layercomprising a first film surface and a second film surface, wherein firstfilm surface contacts the first film layer, wherein the second filmsurface is configured to face away from the tissue joined by thesurgical stapling; and (b) an adhesive located on the second filmsurface of the second film layer, wherein the adhesive is configured toprovide releasable adhesion of the buttress assembly with an endeffector of a surgical stapler.

Example 22

The buttress assembly of Example 21, wherein the mesh layer comprises aknitted textile constructed from an absorbable synthetic material.

Example 23

The buttress assembly of any one or more of Examples 21 and 22, whereinthe mesh layer comprises polyglactin 910.

Example 24

The buttress assembly of any one or more of Examples 21 through 23,wherein the mesh layer comprises a multi-filament structure.

Example 25

The buttress assembly of any one or more of Examples 21 through 24,wherein the first film layer comprises polydioxanone.

Example 26

The buttress assembly of any one or more of Examples 21 through 25,wherein the first film layer has a thickness of about eight micrometers.

Example 27

The buttress assembly of any one or more of Examples 21 through 26,wherein the second film layer comprises an absorbable syntheticmaterial.

Example 28

The buttress assembly of any one or more of Examples 21 through 27,wherein the second film layer comprises poliglycaprone 25.

Example 29

The buttress assembly of any one or more of Examples 21 through 28,wherein the second film layer has a thickness of about ten micrometers.

Example 30

The buttress assembly of any one or more of Examples 21 through 29,wherein the second film layer is configured as an adhesion barrier toprevent tissue adhesions.

Example 31

The buttress assembly of any one or more of Examples 21 through 30,wherein the multi-layer base material is formed by laminating the meshlayer, the first film layer, and the second film layer together byapplying a predetermined pressure and predetermined heat over apredetermined time.

Example 32

The buttress assembly of any one or more of Examples 21 through 31,wherein the multi-layer base material of the buttress assembly comprisescut edges.

Example 33

The buttress assembly of any one or more of Examples 21 through 32,wherein the mesh layer defines a knit pattern, wherein the knit patternis oriented at about 45 degrees relative to a longitudinal axis of thebuttress assembly.

Example 34

The buttress assembly of any one or more of Examples 21 through 33,wherein the mesh layer comprises a plurality of openings that areconfigured to promote tissue ingrowth.

Example 35

The buttress assembly of any one or more of Examples 21 through 34,wherein the plurality of openings are defined by a knitted textileconstructed from an absorbable synthetic material.

Example 36

A buttress, configured for use with an end effector of a surgicalstapler, is further configured for reinforcing a surgically stapledsite. The buttress comprises (a) a mesh layer knitted from amulti-filament absorbable synthetic material, wherein the mesh layerdefines a plurality of openings. On a first side of the mesh layer theplurality of openings are configured to face the surgically stapled siteand contact tissue to promote tissue ingrowth. The buttress furthercomprises (b) a film layer located opposite to the first side of themesh layer with the exposed plurality of openings, wherein the filmlayer is configured to face away from the surgically stapled site andprevent tissue adhesions at and around the surgically stapled site.

Example 37

The buttress of Example 36, wherein the mesh layer comprises polyglactin910, and wherein the film layer comprises poliglycaprone 25.

Example 38

The buttress of any one or more of Examples 36 and 37, furthercomprising an adhesive layer positioned between the mesh layer and thefilm layer, wherein the adhesive layer is configured to adhesively bondthe mesh layer with the film layer to form a laminate, wherein theadhesive layer comprises polydioxanone.

Example 39

A method of reinforcing tissue at a surgically stapled site comprises(a) positioning an end effector of a surgical stapler relative to abuttress applicator. The buttress applicator selectively retains abuttress comprising (i) a mesh layer knitted from a multi-filamentabsorbable synthetic material. The mesh layer defines a plurality ofopenings, wherein on a first side of the mesh layer the plurality ofopenings are configured to face the surgically stapled site and contacttissue to promote tissue ingrowth. The buttress further comprises (ii) afilm layer located opposite to the first side of the mesh layer with theexposed plurality of openings. The film layer is configured to face awayfrom the surgically stapled site and prevent tissue adhesions at andaround the surgically stapled site. The method further comprises (b)clamping the end effector onto a portion of the buttress applicator,wherein the act of clamping causing disengagement of retention featuresof the buttress applicator from the buttress. The act of clampingfurther causes the buttress to releasably attach with the end effectorvia an adhesive located on the buttress. The method further comprises(c) separating the end effector from the buttress applicator, (d)positioning the end effector relative to the tissue to be surgicallystapled, and (e) stapling the tissue. The act of stapling the tissuecomprises applying the buttress to the surgically stapled site with thefirst side of the mesh layer facing the surgically stapled site, andwith the film layer facing away from the surgically stapled site to actas an adhesion barrier.

Example 40

The method of Example 39, further comprising prior to the buttress beingloaded onto the buttress applicator, the buttress is mechanical cut froma larger piece, wherein the cutting avoids overheating the buttress,thereby preventing charred edges

Example 41

A packaging assembly for an applicator is configured for loading abuttress assembly onto an end effector of a surgical stapler. Thepackaging assembly comprises: (a) an outer tray; (b) a pouch having atop layer, a bottom layer, and an interior between the top and bottomlayers, wherein the top layer and the bottom layer are connectable toform a selective hermetic seal around the interior, and wherein thebottom layer of the pouch is configured to be contacted by the outertray; (c) an inner tray configured to be positionable within theinterior of the pouch such that the bottom layer of the pouch separatesthe inner tray from the outer tray; and (d) a desiccant material,wherein the inner tray is configured to selectively retain the desiccantmaterial, wherein the desiccant material is configured to absorb anymoisture within the interior of the pouch.

Example 42

The packaging assembly of Example 41, wherein the outer tray isconfigured to protect the bottom layer of the pouch from damage byfitting closely against the bottom layer of the pouch.

Example 43

The packaging assembly of any one or more of Examples 41 through 42,wherein the pouch is made of foil.

Example 44

The packaging assembly of any one or more of Examples 41 through 43,wherein the top layer of the pouch and the bottom layer of the pouch areeach configured to closely follow the contour of the inner tray so as toprotect the pouch from damage.

Example 45

The packaging assembly of any one or more of Examples 41 through 44,wherein the inner tray is further configured to selectively retain theapplicator.

Example 46

The packaging assembly of any one or more of Examples 41 through 45,wherein the inner tray comprises a base, a flap, and a living hingeconnecting the flap with the base.

Example 47

The packaging assembly of Example 46, wherein the base is configured toselectively retain the applicator, and wherein the flap is configured torotate from a closed position to an open position, wherein in the closedposition the flap at least partially covers the applicator when theapplicator is selectively retained within the base.

Example 48

The packaging assembly of any one or more of Examples 46 through 47,wherein the inner tray further comprises at least one fastening featureconfigured to selectively connect the flap with the base.

Example 49

The packaging assembly of Example 48, wherein the at least one fasteningfeature comprises first and second fastening members configured toengage one another when the flap is in the closed position when theapplicator is properly positioned within the base, and wherein the firstand second fastening members are further configured to not engage oneanother when the applicator is improperly positioned within the base.

Example 50

The packaging assembly of any one or more of Examples 41 through 49,wherein the inner tray is configured such that a first end of theapplicator is only positionable within the tray facing one way.

Example 51

The packaging assembly of any one or more of Examples 41 through 50,wherein the inner tray comprises an area on an outer surface of theinner tray, wherein the area is configured to selectively retain thedesiccant material such that the desiccant material does not contact theapplicator.

Example 52

The packaging assembly of any one or more of Examples 41 through 51,wherein the inner tray comprises a base configured to selectively retainthe applicator, and wherein the inner tray comprises a flap connectablewith the base, wherein when the flap is in a closed position the flap isconfigured to shield a buttress assembly of the applicator so that thebuttress assembly is inaccessible.

Example 53

The packaging assembly of any one or more of Examples 41 through 52,wherein the inner tray comprises a flap having a peninsula portionconfigured for grasping when opening the flap.

Example 54

The packaging assembly of any one or more of Examples 41 through 53,wherein the inner tray comprises a molded plastic.

Example 55

The packaging assembly of any one or more of Examples 41 through 54,wherein the desiccant material comprises a paperboard.

Example 56

A packaging assembly for one or more buttresses is configured for usewith a surgical stapler. The packaging assembly comprises (a) an outertray, and (b) an inner tray configured to selectively retain anapplicator. The applicator is configured for selectively retaining theone or more buttresses, and for loading the one or more buttresses ontoan end effector of the surgical stapler. The packaging assembly furthercomprises (c) an impermeable material positionable between the outertray and the inner tray. The impermeable material surrounds theapplicator selectively retained by the inner tray forming a hermeticseal around the inner tray and applicator.

Example 57

The packaging assembly of Example 56, wherein the outer tray isconfigured to protect the impermeable material from damage.

Example 58

A method for packaging an applicator having a buttress assemblyconfigured to be loaded onto an end effector of a surgical stapler. Themethod comprising: (a) positioning the applicator within a base of aninner tray; (b) securing a movable flap in a closed positioned, whereinin the closed position the movable flap is retained against the base ofthe inner tray by one or more fastening features; (c) positioning theinner tray with the applicator between a first foil layer and a secondfoil layer; and (d) attaching the first foil layer with the second foillayer to define a foil assembly that surrounds the inner tray with theapplicator to create a hermetic seal around the inner tray with theapplicator.

Example 59

The method of Example 58, further comprising positioning the foilassembly containing the inner tray with the applicator within an outertray configured to prevent damage to the foil assembly.

Example 60

The method of any one or more of Examples 58 through 59, whereinpositioning the applicator within a base of the inner tray comprisesorienting the applicator in one direction so that the applicator sitsflat within the base of the inner tray and allows the flap to properlyclose.

Example 61

A surgical system for stapling tissue, comprising: (a) a buttressapplier cartridge, including: (i) a housing defining a first gap and asecond gap extending in a longitudinal direction therealong such thateach of the first and second gaps are configured to receive a firstportion of an end effector and a second portion of the end effector of asurgical stapler, and (ii) a platform connected to the housing andexposed in a transverse direction between the first and second gaps andsupported by the housing, (b) a first buttress assembly positioned onthe platform and exposed in the first gap of the housing, wherein thefirst buttress includes: (i) a first buttress configured to be receivedagainst tissue and support a staple formed therein, and (ii) a firstadhesive layer on the first buttress exposed in the first gap of thehousing and configured to releasably adhere the first buttress againstthe first or second portion of the end effector, wherein the firstadhesive layer is parallel to the first buttress and defines a firstadhesive pattern having a first outer adhesive profile; and (c) a secondbuttress assembly positioned on the platform and exposed in the secondgap of the housing, wherein the second buttress includes: (i) a secondbuttress configured to be received against tissue and support the stapleformed therein, and (ii) a second adhesive layer on the second buttressexposed in the second gap of the housing and configured to releasablyadhere the second buttress against the first or second portion of theend effector, wherein the second adhesive layer is parallel to thesecond buttress and defines a second adhesive pattern having a secondouter adhesive profile, wherein the exposed second outer adhesiveprofile in the transverse direction is the same as the exposed firstouter adhesive profile in an opposite transverse direction such that thefirst and second buttress assemblies are interchangeable with the firstand second portions of the end effector of the surgical instrument.

Example 62

The surgical system of Example 61, wherein the second adhesive patternof the second adhesive layer mirrors the first adhesive pattern of thefirst adhesive layer through the platform.

Example 63

The surgical system of any one or more of Examples 61 through 62,wherein the first buttress assembly is transversely offset from andtransversely aligned with the second buttress assembly.

Example 64

The surgical system of any one or more of Examples 61 through 63,wherein the first outer adhesive profile is transversely offset from andtransversely aligned with the second outer adhesive profile.

Example 65

The surgical system of any one or more of Examples 61 through 64,wherein the first adhesive layer is a first adhesive bead layer, andwherein the second adhesive layer is a second adhesive bead layer.

Example 66

The surgical system of any one or more of Examples 61 through 65,wherein the first buttress assembly has a first lateral buttress widthin a lateral direction perpendicular to the longitudinal and transversedirections, wherein the second buttress assembly has a second lateralbuttress width in the lateral direction perpendicular to thelongitudinal and transverse directions, wherein the first and secondlateral buttress widths are each the same.

Example 67

The surgical system of Example 66, wherein the first and second lateralbuttress widths are each 0.41 inches.

Example 68

The surgical system of any one or more of Examples 61 through 67,wherein the first and second adhesive layers are each configured toadhere to an anvil of the end effector and a staple cartridge of an endeffector, wherein the first and second adhesive layers are eachconfigured to adhere to the anvil with a lesser adhesive surface areafor relatively reduced adhesion thereto, and wherein the first andsecond adhesive layers are configured to adhere to the staple cartridgewith a greater adhesive surface area for relatively increased adhesionthereto.

Example 69

The surgical system of Example 68, wherein the first and second outeradhesive profiles are each configured to laterally fit within an outerstapler cartridge profile of the staple cartridge adhered thereto in alateral direction perpendicular to the longitudinal and transversedirections, and wherein the first and second outer adhesive profiles areeach configured to laterally extend beyond an outer anvil profile of theanvil adhered thereto in the lateral direction perpendicular to thelongitudinal and transverse directions.

Example 70

The surgical system of Example 69, further comprising a surgical staplerhaving an end effector, wherein the end effector includes a staplecartridge movably mounted relative to an anvil and the staple cartridgeremovably adhered to one of the first or second buttress assemblies andthe anvil removably adhered to the other of the first or second buttressassemblies, wherein one of the first or second outer adhesive profileslaterally fits within the outer stapler cartridge profile of the staplecartridge adhered thereto, and wherein the other of the first or secondouter adhesive profiles laterally extends beyond the outer anvil profileof the anvil adhered thereto.

Example 71

The surgical system of any one or more of Examples 61 through 70,wherein at least one of the first or second buttresses has a pre-cutslit extending longitudinally therealong, wherein the pre-cut slit isconfigured to receive a knife for separating the at least one of thefirst or second buttress assemblies.

Example 72

The surgical system of Example 71, wherein the at least one of the firstor second buttresses includes a distal buttress end portion, a proximalbuttress end portion, and an intermediate buttress portion extendingtherebetween, wherein the pre-cut slit includes at least one of aproximal end slit longitudinally extending through the proximal buttressend portion to a proximal end of the proximal buttress end portion, adistal end slit longitudinally extending through the distal buttress endportion to a distal end of the distal buttress end portion, or anintermediate slit longitudinally extending through the intermediatebuttress portion.

Example 73

The surgical system of Example 72, wherein the pre-cut slit includeseach of the proximal end slit, the distal end slit, and the intermediateslit therebetween, and wherein the intermediate slit is longitudinallyspaced apart from each of the proximal and distal end slits.

Example 74

The surgical system of any one or more of Examples 61 through 73,wherein at least one of the first or second buttresses has a core layersandwiched between a pair of outer layers.

Example 75

The surgical system of Example 74, wherein the core layer is apolyglactin 910 material, and wherein the outer layers are each apolydioxanone film material.

Example 76

A buttress applier cartridge assembly, comprising: (a) a buttressassembly configured to be positioned on a platform and exposed in a gapof a housing, wherein the buttress assembly includes: (i) a buttressextending longitudinally from a proximal buttress end portion to adistal buttress end portion with an intermediate buttress portionextending therebetween, wherein the buttress is configured to bereceived against tissue and support a staple formed therein, (ii) anadhesive layer on the buttress extending in a longitudinal direction anda lateral direction perpendicular to the longitudinal direction, whereinthe adhesive layer is configured to be exposed in the gap of the housingand further configured to releasably adhere the buttress against an endeffector of a surgical stapler, and (iii) a pre-cut slit extendinglongitudinally through the buttress and configured to receive a knife asthe knife cuts through a proximal buttress end portion through theintermediate buttress portion to the distal buttress end portion,wherein the pre-cut slit is configured to encourage separating a firstlateral portion of the buttress from a second lateral portion of thebuttress.

Example 77

The buttress applier cartridge of Example 76, wherein the pre-cut slitincludes a proximal end slit longitudinally extending through theproximal buttress end portion to a proximal end of the proximal buttressend portion.

Example 78

The buttress applier cartridge of any one or more of Examples 76 through77, wherein the pre-cut slit includes a distal end slit longitudinallyextending through the distal end portion to a distal end of the distalbuttress end portion.

Example 79

The buttress applier cartridge of Examples 76 through 78, wherein thepre-cut slit includes an intermediate slit longitudinally extendingthrough the intermediate buttress portion.

Example 80

A buttress applier cartridge assembly, comprising: (a) a buttressassembly configured to be positioned on a platform and exposed in a gapof a housing, wherein the buttress assembly includes: (i) a buttressconfigured to be received against tissue and support a staple formedtherein, wherein the buttress includes: (A) a first outer film layer,(B) a second outer film layer, and (C) a core mesh layer laminatedbetween the first and second outer layers; and (ii) an adhesive layer onthe first outer layer configured to be exposed in the gap of the housingand further configured to releasably adhere the buttress against an endeffector of a surgical stapler, wherein each of the first and secondouter film layers, the core mesh layer, and the adhesive layer areconfigured to be absorbed by tissue.

Example 81

A buttress applier cartridge assembly, comprising: (a) a first buttressassembly, including: (i) a first buttress configured to be receivedagainst tissue and support a staple formed therein, and (ii) a firstadhesive layer on the first buttress configured to releasably adhere thefirst buttress against a first portion of an end effector of a surgicalstapler upon engaging the first adhesive layer against the end effectorwith at least a predetermined minimum force; and (b) a buttress appliercartridge, including: (i) a housing defining a first gap extending in alongitudinal direction therealong such that the first gap is configuredto receive the first portion of the end effector, and (ii) a platformextending longitudinally from a proximal platform portion to a distalplatform portion and operatively connected to the housing, wherein theplatform is exposed in a transverse direction adjacent to the first gapand the proximal and distal platform portions respectively have aproximal stiffness and a different, distal stiffness in the transversedirection, wherein the proximal and distal platform portions support thefirst buttress assembly thereon and are configured to deform with theproximal and distal stiffnesses thereby providing reactionary forces ofat least the predetermined minimum force while receiving the endeffector for accommodating various camber orientations of the endeffector.

Example 82

The buttress applier cartridge assembly of Example 81, furthercomprising: (a) a second buttress assembly, including: (i) a secondbuttress configured to be received against tissue and support the stapleformed therein, and (ii) a second adhesive layer on the second buttressconfigured to releasably adhere the second buttress against a secondportion of the end effector upon engaging the second adhesive layeragainst the end effector with at least the predetermined minimum force;and (b) the buttress applier cartridge, further including: (i) thehousing defining a second gap extending in the longitudinal directiontherealong such that the second gap is configured to receive the secondportion of the end effector, and (ii) the platform exposed in thetransverse direction between the first and second gaps, wherein theproximal and distal platform portions support the first and secondbuttress assemblies on opposing transverse sides thereof and areconfigured to deform with the proximal and distal stiffnesses therebyproviding reactionary forces of at least the predetermined minimum forcewhile receiving the end effector for accommodating various camberorientations of the first portion of the end effector relative to thesecond portion of the end effector.

Example 83

The buttress applier cartridge assembly of any one or more of Examples81 through 82, wherein the proximal platform portion has a proximaltransverse depth, wherein the distal platform portion has a distaltransverse depth, and wherein the proximal transverse depth is less thanthe distal transverse depth.

Example 84

The buttress applier cartridge assembly of any one or more of Examples81 through 83, wherein the platform continuously tapers from the distalplatform portion toward the proximal platform portion.

Example 85

The buttress applier cartridge assembly of any one or more of Examples81 through 84, wherein the platform is wedge-shaped.

Example 86

The buttress applier cartridge assembly of any one or more of Examples81 through 85, wherein the platform includes a platform pad and aplurality of reliefs in at least one of the proximal and distal platformportions, wherein the plurality of reliefs are configured to generatethe differing proximal and distal stiffnesses in the platform.

Example 87

The buttress applier cartridge assembly of Example 86, wherein theplurality of reliefs include a plurality of channels, wherein theplurality of channels extend transversely into the platform pad andlongitudinally along the proximal and distal platform portions.

Example 88

The buttress applier cartridge assembly of Example 87, wherein theplatform pad includes a plurality of ribs extending longitudinally alongthe proximal and distal platform portions such that the plurality ofchannels are respectively defined between the plurality of ribs.

Example 89

The buttress applier cartridge assembly of Example 88, wherein theproximal platform portion has a proximal transverse depth, wherein theproximal platform portion has a distal transverse depth, and wherein theproximal transverse depth is less than the distal transverse depth.

Example 90

The buttress applier cartridge assembly of Example 89, wherein theplatform pad continuously tapers from the distal platform portion towardthe proximal platform portion.

Example 91

The buttress applier cartridge assembly of Example 90, wherein theplatform pad is wedge-shaped.

Example 92

The buttress applier cartridge assembly of any one or more of Examples86 through 91, wherein the platform pad is unitarily formed from aresilient material.

Example 93

The buttress applier cartridge assembly of any one or more of Examples81 through 92, further comprising a chassis connected to the housing andhaving a rigid web portion defining a plurality of holes, and whereinthe rigid web portion extends laterally through the platform therebysecuring the rigid web portion of the chassis to the platform.

Example 94

The buttress applier cartridge assembly of any one or more of Examples81 through 93, further comprising: (a) an actuator sled operativelyconnected to the housing and configured to selectively move relative tothe housing from a restraint position to a release position, wherein theactuator sled in the restraint position is configured to capture thefirst buttress assembly to the platform, and wherein actuator sled inthe release position is configured to release the first buttressassembly from the platform for removing the first buttress assemblytherefrom; and (b) a detent coupling operatively connected to theactuator sled and configured arrest movement of the actuator sled in therestraint position when the actuator sled is in the restraint position,and wherein the detent coupling is further configured to arrest movementof the actuator sled in the release position when the actuator sled isin the release position.

Example 95

The buttress applier cartridge assembly of any one or more of Examples81 through 94, wherein the proximal platform portion has a proximaltransverse depth, wherein the distal platform portion has a distaltransverse depth, and wherein the proximal transverse depth is differentthan the distal transverse depth, and wherein the buttress appliercartridge further comprises: (a) an actuator sled operatively connectedto the housing and configured to selectively move relative to thehousing from a restraint position to a release position, wherein theactuator sled in the restraint position is configured to capture thefirst buttress assembly to the platform, and wherein actuator sled inthe release position is configured to release the first buttressassembly from the platform for removing the first buttress assemblytherefrom, wherein the actuator sled further includes: (i) a distal armextending laterally toward the first buttress assembly andlongitudinally aligned with the distal platform portion, and (ii) aproximal arm extending laterally toward the first buttress assembly andlongitudinally aligned with the proximal platform portion, wherein thedistal arm is transversely offset relative to the proximal arm such thatthe distal and proximal arms respectively engage the first buttressassembly at the distal and proximal platform portions in the restraintposition.

Example 96

A buttress applier cartridge assembly, comprising: (a) a first buttressassembly, including: (i) a first buttress configured to be receivedagainst tissue and support a staple formed therein, and (ii) a firstadhesive layer on the first buttress configured to releasably adhere thefirst buttress against a first portion of an end effector of a surgicalstapler upon engaging the first adhesive layer against the end effectorwith at least a predetermined minimum force; (b) a buttress appliercartridge, including: (i) a housing defining a first gap extending in alongitudinal direction therealong such that the first gap is configuredto receive the first portion of the end effector, and (ii) a platformextending longitudinally from a proximal platform portion to a distalplatform portion and operatively connected to the housing, wherein theplatform is exposed in a transverse direction adjacent to the first gap,wherein the proximal and distal platform portions support the firstbuttress assembly thereon; (c) a first actuator sled operativelyconnected to the housing and configured to selectively move relative tothe housing from a first restraint position to a first release position,wherein the first actuator sled in the first restraint position isconfigured to capture the first buttress assembly to the platform, andwherein actuator sled in the first release position is configured torelease the first buttress assembly from the platform for removing thefirst buttress assembly therefrom; and (d) a first detent couplingoperatively connected to the first actuator sled and configured arrestmovement of the first actuator sled in the restraint position when thefirst actuator sled is in the first restraint position, and wherein thefirst detent coupling is further configured to arrest movement of thefirst actuator sled in the first release position when the firstactuator sled is in the first release position.

Example 97

The buttress applier cartridge assembly of Example 96, furthercomprising: (a) a second buttress assembly, including: (i) a secondbuttress configured to be received against tissue and support the stapleformed therein, and (ii) a second adhesive layer on the second buttressconfigured to releasably adhere the second buttress against a secondportion of the end effector upon engaging the second adhesive layeragainst the end effector with at least the predetermined minimum force;and (b) the buttress applier cartridge, further including: (i) thehousing defining a second gap extending in the longitudinal directiontherealong such that the second gap is configured to receive the secondportion of the end effector, and (ii) the platform exposed in thetransverse direction between the first and second gaps, wherein theproximal and distal platform portions support the first and secondbuttress assemblies on opposing transverse sides thereof.

Example 98

The buttress applier cartridge assembly of any one or more of Examples96 through 97, further comprising: (a) a second actuator sledoperatively connected to the housing and configured to selectively moverelative to the housing from a second restraint position to a secondrelease position, wherein the second actuator sled in the secondrestraint position is configured to capture the first buttress assemblyto the platform, and wherein actuator sled in the second releaseposition is configured to release the first buttress assembly from theplatform for removing the first buttress assembly therefrom; and (b) asecond detent coupling operatively connected to the second actuator sledand configured arrest movement of the second actuator sled in therestraint position when the second actuator sled is in the secondrestraint position, and wherein the second detent coupling is furtherconfigured to arrest movement of the second actuator sled in the secondrelease position when the first actuator sled is in the second releaseposition.

Example 99

The buttress applier cartridge assembly of any one or more of Examples96 through 98, wherein the proximal platform portion has a proximaltransverse depth, wherein the distal platform portion has a distaltransverse depth, and wherein the proximal transverse depth is differentthan the distal transverse depth, and wherein the first actuator sledfurther includes a distal arm and a proximal arm, wherein the distal armextends laterally toward the first buttress assembly and longitudinallyaligned with the distal platform portion, wherein the proximal armextends laterally toward the first buttress assembly and islongitudinally aligned with the proximal platform portion, and whereinthe distal arm is transversely offset relative to the proximal arm suchthat the distal and proximal arms respectively engage the first buttressassembly at the distal and proximal platform portions in the restraintposition.

Example 100

A buttress applier cartridge assembly, comprising: (a) a buttressassembly, including: (i) a buttress configured to be received againsttissue and support a staple formed therein, and (ii) an adhesive layeron the buttress configured to releasably adhere the buttress against aportion of an end effector of a surgical stapler upon engaging theadhesive layer against the end effector with at least a predeterminedminimum force; (b) a buttress applier cartridge, including: (i) ahousing defining a gap extending in a longitudinal direction therealongsuch that the gap is configured to receive the portion of the endeffector, and (ii) a platform extending longitudinally from a proximalplatform portion to a distal platform portion and operatively connectedto the housing, wherein the platform is exposed in a transversedirection adjacent to the gap and supports the buttress assemblythereon, wherein proximal and distal platform portions respectively havea proximal transverse depth and a distal transverse, wherein theproximal transverse depth is different than the distal transverse depth;and (c) an actuator sled operatively connected to the housing andconfigured to selectively capture the buttress assembly to the platformin a restraint position, wherein the actuator sled, includes: (i) adistal arm extending laterally toward the buttress assembly andlongitudinally aligned with the distal platform portion, and (ii) aproximal arm extending laterally toward the buttress assembly andlongitudinally aligned with the proximal platform portion, wherein thedistal arm is transversely offset relative to the proximal arm such thatthe distal and proximal arms respectively engage the buttress assemblyat the distal and proximal platform portions in the restraint position.

Example 101

A buttress applier cartridge is configured to retain one or morebuttress assemblies. The buttress applier cartridge is furtherconfigured for use with an end effector of a surgical stapler to applythe one or more buttress assemblies to a select one or more of a firstjaw and a second jaw of the end effector. The first jaw of the endeffector comprises an anvil and the second jaw of the end effectorcomprises a staple cartridge. The buttress applier cartridge comprises:(a) a chassis defining an opening extending in a longitudinal directionsuch that the opening is configured to receive the end effector; (b) aplatform extending longitudinally from a proximal platform portion to adistal platform portion and operatively connected to the chassis,wherein the platform supports the one or more buttress assembliesthereon, and wherein the platform increases in thickness from theproximal portion to the distal portion; and (c) an opening that extendstransversely from a first side of the chassis and the platform to asecond side of the chassis and the platform that is opposite the firstside of the chassis and the platform, wherein the opening is sized andconfigured to receive a curved tip of the end effector allowing at leasta portion of the curved tip to extend from the first side of the chassisand the platform to the second side of the chassis and the platform.

Example 102

The buttress applier cartridge of Example 101, wherein the platform iscompressible.

Example 103

The buttress applier cartridge of any one or more of Example 101 throughExample 102, wherein the platform continuously tapers from the distalplatform portion toward the proximal platform portion.

Example 104

The buttress applier cartridge of any one or more of Example 101 throughExample 103, further comprising one or more alignment featuresconfigured to guide the curved tip of the end effector to align the endeffector with the one or more buttress assemblies configured to besupported on the platform.

Example 105

The buttress applier cartridge of any one or more of Example 101 throughExample 104, wherein clamping the end effector on the platform causesthe curved tip of the end effector to contact the one or more alignmentfeatures to align the end effector with the one or more buttressassemblies.

Example 106

The buttress applier cartridge of any one or more of Example 101 throughExample 105, wherein the one or more alignment features are located onan edge of the opening.

Example 107

The buttress applier cartridge of any one or more of Example 101 throughExample 106, further comprising a housing assembly defining a channelconfigured to accommodate the end effector, wherein the channelcomprises a distal end defined by lateral sides, wherein the one or morealignment features are located on the lateral sides.

Example 108

The buttress applier cartridge of any one or more of Example 101 throughExample 107, wherein the one or more alignment features comprise aproximal to distal non-linear decrease in spacing.

Example 109

The buttress applier cartridge of any one or more of Example 101 throughExample 108, wherein the one or more alignment features are formed withor connected with the chassis.

Example 110

The buttress applier cartridge of any one or more of Example 101 throughExample 109, wherein the one or more alignment features comprises a pairof resiliently biased self-centering lateral arms.

Example 111

The buttress applier cartridge of any one or more of Example 101 throughExample 110, wherein the one or more alignment features comprise atapered surface that is configured to contact a tapered side of thecurved tip of the end effector as the end effector is clamped onto theplatform.

Example 112

The buttress applier cartridge of any one or more of Example 101 throughExample 111, wherein the tapered surface of the alignment featuresextends proximally to distally.

Example 113

The buttress applier cartridge of any one or more of Example 101 throughExample 112, wherein the opening is formed in the platform.

Example 114

The buttress applier cartridge of any one or more of Example 101 throughExample 111, wherein the opening is defined by a space between theplatform and the chassis.

Example 115

The buttress applier cartridge of any one or more of Example 101 throughExample 114, wherein an adhesive selectively attaches the one or morebuttress assemblies to the end effector.

Example 116

The buttress applier cartridge of any one or more of Example 101 throughExample 115, wherein the curved tip of the end effector is a dissectingtip.

Example 117

The buttress applier cartridge of any one or more of Example 101 throughExample 116, further comprising movable sleds that each comprises a pairof arms configured for contact by the end effector to drive the movablesleds laterally relative to the platform to release the one or morebuttress assemblies for applying to the end effector.

Example 118

The buttress applier cartridge of any one or more of Example 101 throughExample 117, wherein the platform comprises a curb along the proximalportion, wherein the curb is configured to prevent premature substantialcontact of the first jaw and the second jaw of the end effector with theplatform prior to clamping the end effector.

Example 119

A buttress applier cartridge assembly is configured for use with an endeffector of a surgical stapler. The buttress applier cartridge assemblycomprises: (a) a buttress applier cartridge comprising: (i) a chassisdefining an opening extending in a longitudinal direction such that theopening is configured to receive the end effector, (ii) a platformextending longitudinally from a proximal platform portion to a distalplatform portion and operatively connected to the chassis, (iii) anopening that extends transversely from a first side of the chassis andthe platform to a second side of the chassis and the platform that isopposite the first side of the chassis and the platform, wherein theopening is sized and configured to receive a curved tip of the endeffector allowing at least a portion of the curved tip to extend fromthe first side of the chassis and the platform to the second side of thechassis and the platform, and (iv) an alignment feature configured toguide the curved tip of the end effector during clamping of the endeffector on the platform so that the end effector is substantiallycentered along its longitudinal length relative to the platform; and (b)a buttress assembly comprising: (i) a buttress supported by theplatform, and (ii) an adhesive located on a surface of the buttress,wherein the adhesive is configured to selectively adhere the buttressassembly to a jaw of the end effector when clamping the end effector onthe platform.

Example 120

A buttress applier cartridge is configured to retain one or morebuttress assemblies. The buttress applier cartridge is furtherconfigured for use with an end effector of a surgical stapler having acurved deformable tip, to apply the one or more buttress assemblies to aselect one or more of a first jaw and a second jaw of the end effector.The buttress applier cartridge comprises: (a) a housing defining achannel extending in a longitudinal direction such that the channel isconfigured to receive the end effector, wherein the housing furtherdefines a distal space configured to accommodate the curved deformabletip when the curved deformable tip is in an expanded state; and (b) aplatform extending longitudinally from a proximal platform portion to adistal platform portion and operatively connected to the housingdirectly or indirectly, wherein: (i) the platform supports the one ormore buttress assemblies thereon, (ii) the platform increases inthickness from the proximal portion to the distal portion, (iii) theplatform is compressible when subjected to clamping force from the endeffector, and (iv) the platform is deflectable along the distal platformportion when subjected to clamping force from the end effector.

Example 121

A buttress applier cartridge is configured to retain one or morebuttress assemblies. The buttress applier cartridge is furtherconfigured for use with an end effector of a surgical stapler to applythe one or more buttress assemblies to a select one or more of a firstjaw and a second jaw of the end effector. The first jaw of the endeffector comprises an anvil and the second jaw of the end effectorcomprises a staple cartridge. The buttress applier cartridge comprises(a) a housing assembly having a proximal end and a distal end. Thehousing assembly defines a channel extending longitudinally andconfigured to receive the end effector. The buttress applier cartridgefurther comprises (b) a platform, directly or indirectly connectablewith the housing assembly. The platform extends longitudinally within anarea defined by the channel, and is configured to support the one ormore buttress assemblies thereon. The buttress applier cartridge furthercomprises (c) an opening that extends transversely from a first side ofthe platform to a second side of the platform opposite the first side ofthe platform. The opening is configured to receive a curved tip of theend effector, allowing at least a portion of the curved tip to extendfrom the first side of the platform to the second side of the platform.The buttress applier cartridge further comprises (d) an alignmentfeature connectable with the platform, and extending proximallytherefrom. The alignment feature is configured to contact a tissue stopof the end effector when the end effector is fully positioned within thechannel defined by the housing assembly.

Example 122

The buttress applier cartridge of Example 121, wherein the alignmentfeature is rigid.

Example 123

The buttress applier cartridge of any one or more of Example 121 throughExample 122, wherein the alignment feature is thinner than the platform.

Example 124

The buttress applier cartridge of any one or more of Example 121 throughExample 123, wherein the alignment feature is positioned between wherethe one or more buttress assemblies that are supportable by theplatform.

Example 125

The buttress applier cartridge of any one or more of Example 121 throughExample 124, wherein the alignment feature extends orthogonally relativeto the longitudinally extending channel such that the alignment featureextends across a cut line defined by the end effector when the endeffector is positioned within the channel.

Example 126

The buttress applier cartridge of any one or more of Example 121 throughExample 125, wherein the alignment feature connects with a proximal endof the platform.

Example 127

The buttress applier cartridge of any one or more of Example 121 throughExample 126, wherein the alignment feature is configured to guide thecurved tip of the end effector to align the curved tip of the endeffector with the opening.

Example 128

The buttress applier cartridge of any one or more of Example 121 throughExample 127, wherein the alignment feature is formed as part of theplatform.

Example 129

The buttress applier cartridge of any one or more of Example 121 throughExample 128, wherein the platform increases in thickness from a proximalportion to a distal portion.

Example 130

The buttress applier cartridge of any one or more of Example 121 throughExample 129, wherein the platform is compressible.

Example 131

The buttress applier cartridge of any one or more of Example 121 throughExample 130, further comprising a chassis, wherein the chassis connectswith the housing assembly and the platform connects with the chassis.

Example 132

The buttress applier cartridge of any one or more of Example 121 throughExample 131, wherein the opening comprises a U-shaped cut-out.

Example 133

The buttress applier cartridge of any one or more of Example 121 throughExample 132, wherein the opening is located distal to where the one ormore buttress assemblies are supportable by the platform.

Example 134

The buttress applier cartridge of any one or more of Example 121 throughExample 133, wherein clamping the end effector on the platform causesthe curved tip of the end effector to at least partially extend throughthe opening.

Example 135

The buttress applier cartridge of any one or more of Example 121 throughExample 134, wherein the opening deforms when the curved tip passesthrough the opening.

Example 136

The buttress applier cartridge of any one or more of Example 121 throughExample 135, wherein the opening and alignment feature are spaced suchthat when the tissue stops of the end effector contact the alignmentfeature and the end effector is clamped, the curved tip of the endeffector aligns with and extends through the opening.

Example 137

The buttress applier cartridge of any one or more of Example 121 throughExample 136, further configured such that a proximal edge of a selectone of the first jaw and second jaw of the end effector are used toalign longitudinal position of the end effector relative to the platformand the one or more buttress assemblies configured to be supported bythe platform.

Example 138

The buttress applier cartridge of any one or more of Example 121 throughExample 137, wherein the curved tip of the end effector is a dissectingtip.

Example 139

A buttress applier cartridge assembly is configured for use with an endeffector of a surgical stapler. The buttress applier cartridge assemblycomprises (a) a buttress assembly configured to be selectively adheredthe end effector when clamping the end effector on the buttress appliercartridge assembly. The buttress applier cartridge assembly furthercomprises (b) a buttress applier cartridge selectively retaining thebuttress assembly, wherein the buttress applier cartridge comprises (i)a platform extending longitudinally from a proximal portion to a distalportion. The platform is configured to selectively support the buttressassembly, and to receive the end effector. The buttress appliercartridge further comprises (ii) an opening extending transversely froma first side of the platform to a second side of the platform oppositethe first side of the platform. The opening is configured to receive acurved tip of the end effector allowing at least a portion of the curvedtip to pass through the opening from the first side of the platform tothe second side of the platform. The buttress applier cartridge furthercomprises (iii) an alignment feature located at a proximal end of thebuttress applier cartridge and configured to contact a proximal edge ofthe end effector prior to clamping the end effector on the platform toguide the end effector into alignment with the buttress assemblysupported by the platform prior to clamping the end effector.

Example 140

A buttress application system comprises (a) an end effector for asurgical stapler. The end effector comprises a first jaw and a secondjaw. The first jaw of the end effector comprises an anvil and the secondjaw of the end effector comprises a staple cartridge. The end effectorfurther comprises a curved tip and one or more tissue stops. Thebuttress application system further comprises (b) a pair of buttressassemblies, each comprising a buttress and an adhesive. A first buttressassembly of the pair of buttress assemblies is configured to beselectively adhered to the first jaw of the end effector, and a secondbuttress assembly of the pair of buttress assemblies is configured to beselectively adhered to the second jaw of the end effector. The buttressapplication system further comprises (c) a buttress applier cartridgeconfigured to selectively retain the buttress assemblies and apply thebuttress assemblies to the end effector. The buttress applier cartridgecomprises (i) a housing defining a channel extending longitudinally. Thechannel is open at a proximal end and configured to receive the endeffector. The buttress applier cartridge further comprises (ii) aplatform extending longitudinally and operatively connected to thehousing directly or indirectly. The platform supports the buttressassemblies thereon. The buttress applier cartridge further comprises(iii) an opening that extends transversely from a first side of theplatform to a second side of the platform opposite the first side of theplatform. The opening is configured to receive a curved tip of the endeffector when the end effector is clamped onto the platform. Thebuttress applier cartridge further comprises (iv) an alignment featureconnectable with the platform. The alignment feature extends proximallyfrom the platform. The alignment feature is configured to contact theone or more tissue stops of the end effector when the end effector isopen and positioned within the channel defined by the housing assembly.

Example 141

A buttress applier cartridge is configured to retain one or morebuttress assemblies. The buttress applier cartridge is furtherconfigured for use with an end effector of a surgical stapler to applythe one or more buttress assemblies to a select one or more of a firstjaw and a second jaw of the end effector. The first jaw of the endeffector comprises an anvil and the second jaw of the end effectorcomprises a staple cartridge. The buttress applier cartridge comprises(a) a housing assembly having a proximal end and a distal end. Thehousing assembly defines a channel extending longitudinally andconfigured to receive the end effector. The buttress applier cartridgefurther comprises (b) a platform, directly or indirectly connectablewith the housing assembly. The platform extends longitudinally within anarea defined by the channel. The platform is configured to support theone or more buttress assemblies thereon. The buttress applier cartridgefurther comprises (c) a pocket formed in the platform. The pocket islocated distal to where the platform is configured to support the one ormore buttress assemblies. The pocket is configured to receive a curvedtip of the end effector when clamping the end effector on the platform.

Example 142

The buttress applier cartridge of Example 141, wherein the pocketcomprises a slit in the platform that is configured to deform when thecurved tip of the end effector passes through the pocket.

Example 143

The buttress applier cartridge of any one or more of Example 141 throughExample 142, wherein the pocket comprises a perforated slit.

Example 144

The buttress applier cartridge of Example 143, wherein the perforatedslit provides for a region of the platform that comprises a reducedstiffness such that the region deflects when contacted by the curved tipof the end effector when clamping the end effector on the platform.

Example 145

The buttress applier cartridge of any one or more of Example 141 throughExample 142, wherein the pocket comprises a U-shaped slit.

Example 146

The buttress applier cartridge of Example 145, wherein the U-shaped slitdefines a flap configured to deflect when contacted by the curved tip ofthe end effector when clamping the end effector on the platform.

Example 147

The buttress applier cartridge of any one or more of Example 141 throughExample 142, wherein the pocket comprises a T-shaped slit.

Example 148

The buttress applier cartridge of Example 147, wherein the T-shaped slitdefines a pair of triangular shaped flaps configured to deflect whencontacted by the curved tip of the end effector when clamping the endeffector on the platform.

Example 149

The buttress applier cartridge of any one or more of Example 141 throughExample 148, wherein the pocket is positioned transversely along theplatform between where the one or more buttress assemblies aresupportable by the platform.

Example 150

The buttress applier cartridge of any one or more of Example 141 throughExample 149, wherein the pocket is positioned longitudinally distal towhere the one or more buttress assemblies are supportable by theplatform.

Example 151

The buttress applier cartridge of any one or more of Example 141 throughExample 150, wherein the curved tip of the end effector is a dissectingtip.

Example 152

The buttress applier cartridge of any one or more of Example 141 throughExample 151, further comprising movable sleds that each comprise a pairof arms configured for contact by the end effector to drive the movablesleds laterally relative to the platform to release the one or morebuttress assemblies for applying to the end effector.

Example 153

The buttress applier cartridge of Example 152, wherein the movable sledscomprise a first set of movable sleds positioned above the platform, andwherein the movable sleds comprise a second set of movable sledspositioned below the platform, wherein lateral movement of the first setof movable sleds differs from lateral movement of the second set ofmovable sleds when clamping the end effector on the platform.

Example 154

The buttress applier cartridge of any one or more of Example 141 throughExample 153, wherein the platform comprises a longitudinally extendingcentral region defining a central axis, wherein the platform comprises asmaller thickness along the central axis.

Example 155

The buttress applier cartridge of Example 154, wherein the platformfurther comprises a pair of longitudinally extending outer regions withone of the pair of outer regions located on each side of the centralregion, wherein the thickness of the platform progressively increases asthe platform extends laterally from the central region to the outerregions.

Example 156

The buttress applier cartridge of any one or more of Example 141 throughExample 155, wherein the platform is compressible.

Example 157

A buttress applier cartridge is configured to retain one or morebuttress assemblies. The buttress applier cartridge is furtherconfigured for use with an end effector of a surgical stapler to applythe one or more buttress assemblies to a select one or more of a firstjaw and a second jaw of the end effector. The first jaw of the endeffector comprises an anvil and the second jaw of the end effectorcomprises a staple cartridge. The buttress applier cartridge comprises(a) a housing assembly having a proximal end and a distal end. Thehousing assembly defines a channel extending longitudinally andconfigured to receive the end effector. The buttress applier cartridgefurther comprises (b) a platform, directly or indirectly connectablewith the housing assembly. The platform extends longitudinally within anarea defined by the channel. The platform is configured to support theone or more buttress assemblies thereon. The platform comprises alongitudinally extending central region defining a central axis and apair of longitudinally extending outer regions with one of the pair ofouter regions located on each side of the central region. The platformcomprises a smaller thickness along the central axis relative to thethickness along the pair of outer regions.

Example 158

The buttress applier cartridge of Example 157, wherein the thickness ofthe platform progressively increases as the platform extends laterallyfrom the central region to the outer regions.

Example 159

The buttress applier cartridge of any one or more of Example 157 throughExample 158, further comprising a pocket formed in the platform, whereinthe pocket is located distal to where the platform is configured tosupport the one or more buttress assemblies, wherein the pocket isconfigured to receive a curved tip of the end effector when clamping theend effector on the platform.

Example 160

A buttress applier cartridge assembly is configured for use with an endeffector of a surgical stapler. The buttress applier cartridge assemblycomprises (a) a pair of buttress assemblies, each comprising a buttressand an adhesive, wherein when clamping the end effector on the buttressapplier cartridge assembly a first buttress assembly of the pair ofbuttress assemblies is configured to be selectively adhered to a firstjaw of the end effector, and a second buttress assembly of the pair ofbuttress assemblies is configured to be selectively adhered to a secondjaw of the end effector. The buttress applier cartridge assembly furthercomprises (b) a buttress applier cartridge configured to selectivelyretain the buttress assemblies for applying the buttress assemblies tothe end effector. The buttress applier cartridge comprises (i) a housingassembly having a proximal end and a distal end. The housing assemblydefines a channel extending longitudinally and configured to receive theend effector. The buttress applier cartridge further comprises (ii) aplatform, directly or indirectly connectable with the housing assembly.The platform extends longitudinally within an area defined by thechannel. The platform is configured to support the pair of buttressassemblies thereon. The buttress applier cartridge further comprises(iii) a pocket formed in the platform, wherein the pocket is locateddistal to the pair of buttress assemblies. The pocket is configured toreceive a curved tip of the end effector when clamping the end effectoron the platform to accommodate the curved tip such that the end effectorclamps on the platform to receive the pair of buttress assemblies.

Example 161

A method of applying a buttress assembly to an end effector of asurgical stapler using a buttress applier cartridge configured toselectively retain the buttress assembly, wherein the end effectorcomprises a pair of jaws configured to move between an open unclampedstate and a closed clamped state, wherein the end effector furthercomprises a curved tip, and wherein the buttress assembly comprises abuttress and an adhesive applied to the buttress, the method comprising:positioning the end effector within a channel defined by a housing ofthe buttress applier cartridge, wherein the jaws of the end effector arein the open unclamped state, wherein the buttress applier cartridgecomprises an opening configured to accommodate the curved tip of the endeffector; aligning the end effector within the channel in alongitudinally centered orientation relative to the buttress assemblyselectively retained on a platform of the buttress applier cartridge;clamping the end effector on the platform of the buttress appliercartridge, wherein the platform extends within the channel defined bythe housing of the buttress applier cartridge, wherein the platform iscompressible and comprises a wedge shape, wherein clamping the endeffector on the platform comprises the end effector contacting anactuator sled configured to selectively retain the buttress assembly onthe platform of the buttress applier cartridge, wherein contacting theactuator sled with the end effector moves the actuator sled to releasethe buttress assembly from the platform, and wherein at least a portionof the curved tip of the end effector is received by the opening of thebuttress applier cartridge during clamping; and adhering the buttressassembly to the end effector, wherein adhering the buttress assemblycomprises one of the pair of jaws of the end effector contacting theadhesive on the buttress.

Example 162

The method of Example 161, wherein the opening comprises an edge havinga tapered surface configured to guide the end effector during clamping.

Example 163

The method of any one or more of Examples 161 through 162, furthercomprising guiding the curved tip of the end effector into the openingto promote alignment of the end effector longitudinally relative to thebuttress assembly selectively retained on the platform.

Example 164

The method of Example 163, wherein guiding the curved tip of the endeffector comprises the curved tip of the end effector contacting thetapered surface of the edge of the opening during clamping.

Example 165

The method of any one or more of Examples 161 through 164, wherein theopening comprises a slit.

Example 166

The method of any one or more of Examples 161 through 165, wherein theopening is expandable as the curved tip extends through the openingduring clamping.

Example 167

The method of any one or more of Examples 161 through 166, wherein thebuttress applier cartridge comprises a proximal alignment featureconfigured to contact a tissue stop of the end effector prior toclamping.

Example 168

The method of Example 167, wherein aligning the end effector within thechannel comprises the tissue stop of the end effector contacting theproximal alignment feature.

Example 169

The method of any one or more of Examples 167 through 168, wherein theproximal alignment feature comprises a rigid structure that extendsproximally from the platform and is thinner than the platform.

Example 170

The method of any one or more of Examples 161 through 169, wherein theopening comprises a U-shaped slit.

Example 171

The method of any one or more of Examples 161 through 170, furthercomprising opening the end effector after clamping on the platform andremoving the end effector from the channel defined by the buttressapplier cartridge.

Example 172

The method of any one or more of Examples 161 through 171, wherein theopening is defined by a hole in a distal portion of the platform,wherein the opening is located distal to where the buttress isselectively retained on the platform.

Example 173

The method of any one or more of Examples 161 through 172, wherein thebuttress applier cartridge comprises a distal alignment featureconfigured to contact the curved tip of the end effector duringclamping.

Example 174

The method of any one or more of Examples 161 through 173, wherein thedistal alignment feature comprises a pair of resiliently biasedself-centering lateral arms arranged about the opening.

Example 175

The method of any one or more of Examples 161 through 174, wherein thecurved tip of the end effector is a dissecting tip.

Example 176

A method of applying a first buttress assembly and a second buttressassembly to a first jaw and a second jaw of an end effector of asurgical stapler, wherein each of the first and the second buttressassemblies comprises a buttress and an adhesive applied to the buttress.the method comprising: positioning an open end of a buttress appliercartridge adjacent to the end effector of the surgical stapler, whereinthe buttress applier cartridge is configured to selectively retain thefirst and second buttress assemblies on opposing surfaces of a platformof the buttress applier cartridge; positioning the end effector, in anopen unclamped state, within a channel defined by a housing of thebuttress applier cartridge such that the first jaw of the end effectoris located adjacent to the first buttress assembly, and the second jawof the end effector is located adjacent to the second buttress assembly;guiding the end effector relative to the buttress applier cartridge toalign a curved tip of the end effector with a pocket formed in theplatform of the buttress applier cartridge, wherein the pocket isconfigured to accommodate the curved tip of the end effector when theend effector is in a clamped closed state; clamping the end effector onthe platform of the buttress applier cartridge, wherein clamping the endeffector on the platform comprises the first jaw of the end effectorcontacting a first pair of actuator sleds to selectively release thefirst buttress assembly from the platform of the buttress appliercartridge, wherein clamping the end effector on the platform furthercomprises the second jaw of the end effector contacting a second pair ofactuator sleds to selectively release the second buttress assembly fromthe platform of the buttress applier cartridge, and wherein at least aportion of the curved tip of the end effector is received by the pocketof the buttress applier cartridge during clamping; adhering the firstbuttress assembly to the first jaw of the end effector, wherein adheringthe first buttress assembly comprises the first jaw of the end effectorcontacting the adhesive on the buttress of the second buttress assembly;adhering the second buttress assembly to the second jaw of the endeffector, wherein adhering the second buttress assembly comprises thesecond jaw of the end effector contacting the adhesive on the buttressof the second buttress assembly; and opening the end effector afterclamping on the platform and removing the end effector from the channeldefined by the buttress applier cartridge.

Example 177

The method of Example 176, wherein the pocket comprises a slit in theplatform.

Example 178

The method of Example 177, wherein the slit is perforated.

Example 179

The method of any one or more of Examples 176 through 178, wherein thebuttress applier cartridge comprises a proximal alignment featureconfigured to contact a proximal edge of the end effector when in theopen unclamped state to align the end effector longitudinally relativeto the channel defined by the housing of the buttress applier cartridge.

Example 180

A method of applying a buttress assembly to an end effector of asurgical stapler using a buttress applier cartridge configured toselectively retain the buttress assembly, wherein the end effectorcomprises a pair of jaws configured to move between an open unclampedstate and a closed clamped state, and wherein the buttress assemblycomprises a buttress and an adhesive applied to the buttress, the methodcomprising: positioning the end effector within a channel defined by ahousing of the buttress applier cartridge, wherein the jaws of the endeffector are in the open unclamped state; aligning the end effectorwithin the channel in a longitudinally centered orientation relative tothe buttress assembly selectively retained on a platform of the buttressapplier cartridge, wherein the buttress applier cartridge comprises aproximal alignment feature configured to contact a tissue stop of theend effector prior to clamping, and wherein aligning the end effectorwithin the channel comprises the tissue stop of the end effectorcontacting the proximal alignment feature; clamping the end effector onthe platform of the buttress applier cartridge, wherein the platformextends within the channel defined by the housing of the buttressapplier cartridge, wherein clamping the end effector on the platformcomprises the end effector contacting an actuator sled configured toselectively retain the buttress assembly on the platform of the buttressapplier cartridge, wherein contacting the actuator sled with the endeffector moves the actuator sled to release the buttress assembly fromthe platform; and adhering the buttress assembly to the end effector,wherein adhering the buttress assembly comprises one of the pair of jawsof the end effector contacting the adhesive on the buttress.

XX. Miscellaneous

While the terms “buttress” and “buttress assembly” are used throughoutthis disclosure, it should be understood that the term is not intendedto limit the scope of the present invention in any way. For instance,use of the terms “buttress” and “buttress assembly” is not intended todemonstrate contemplation that a “buttress” or “buttress assembly” canonly be used to provide structural support to a staple line or serve anyother particular purpose. It is contemplated that “buttress” or“buttress assembly” may serve a variety of purposes in addition to or asan alternative to providing structural support to a staple line. Theterms “buttress” and “buttress assembly” should therefore be readbroadly to include any kind of adjunct to a staple line that serves anysuitable purpose.

It should be understood that any one or more of the teachings,expressions, embodiments, examples, etc. described herein may becombined with any one or more of the other teachings, expressions,embodiments, examples, etc. that are described herein. Theabove-described teachings, expressions, embodiments, examples, etc.should therefore not be viewed in isolation relative to each other.Various suitable ways in which the teachings herein may be combined willbe readily apparent to those of ordinary skill in the art in view of theteachings herein. Such modifications and variations are intended to beincluded within the scope of the claims.

It should also be understood that the teachings herein may be readilycombined with various teachings in U.S. Pat. No. D836,198, entitled“Surgical Stapler End Effector with Varying Deck Height and TissueGripping Features,” issued Dec. 18, 2018, the disclosure of which isincorporated by reference herein. Various suitable ways in which theteachings herein may be combined with the teachings of U.S. Pat. No.D836,198, will be apparent to those of ordinary skill in the art.

It should also be understood that the teachings herein may be readilycombined with various teachings in U.S. Pat. No. D833,010, entitled“Circular Surgical Stapler End Effector with Varying Deck Height andTissue Gripping Features,” issued Nov. 6, 2018, the disclosure of whichis incorporated by reference herein. Various suitable ways in which theteachings herein may be combined with the teachings of U.S. Pat. No.D833,010, will be apparent to those of ordinary skill in the art.

It should also be understood that the teachings herein may be readilycombined with various teachings in U.S. Pat. Pub. No. 2018/0235610,entitled “Surgical Stapler with Insertable Distal Anvil Tip,” publishedAug. 23, 2018, the disclosure of which is incorporated by referenceherein. Various suitable ways in which the teachings herein may becombined with the teachings of U.S. Pat. Pub. No. 2018/0235610, will beapparent to those of ordinary skill in the art.

It should also be understood that the teachings herein may be readilycombined with various teachings in U.S. Pat. Pub. No. 2018/0235611,entitled “Surgical Stapler with Cooperating Distal Tip Features on Anviland Staple Cartridge,” published Aug. 23, 2018, the disclosure of whichis incorporated by reference herein. Various suitable ways in which theteachings herein may be combined with the teachings of U.S. Pat. Pub.No. 2018/0235611, will be apparent to those of ordinary skill in theart.

It should also be understood that the teachings herein may be readilycombined with various teachings in U.S. Pat. No. D836,199, entitled“Surgical Stapler with Bent Anvil Tip and Angled Staple Cartridge Tip,”issued Dec. 18, 2018, the disclosure of which is incorporated byreference herein. Various suitable ways in which the teachings hereinmay be combined with the teachings of U.S. Pat. No. D836,199, will beapparent to those of ordinary skill in the art.

It should also be understood that the teachings herein may be readilycombined with various teachings in U.S. Pat. Pub. No. 2018/0235619,entitled “Surgical Stapler with Bent Anvil Tip, Angled Staple CartridgeTip, and Tissue Gripping Features,” published Aug. 23, 2018, thedisclosure of which is incorporated by reference herein. Varioussuitable ways in which the teachings herein may be combined with theteachings of U.S. Pat. Pub. No. 2018/0235619, will be apparent to thoseof ordinary skill in the art.

It should also be understood that the teachings herein may be readilycombined with various teachings in U.S. patent application Ser. No.16/035,893, entitled “Method of Surgical Stapling with End EffectorsHaving a Curved Tip,” filed Jul. 16, 2018, the disclosure of which isincorporated by reference herein. Various suitable ways in which theteachings herein may be combined with the teachings of U.S. patentapplication Ser. No. 16/035,893, will be apparent to those of ordinaryskill in the art.

In addition to the foregoing, it should also be understood that any ofthe various buttress assemblies described herein may be furtherconstructed and operable in accordance with at least some of theteachings of U.S. Pat. Pub. No. 2016/0278774, entitled “Method ofApplying a Buttress to a Surgical Stapler,” published Sep. 29, 2016, thedisclosure of which is incorporated by reference herein; U.S. Pat. Pub.No. 2017/0049444, entitled “Implantable Layers for a SurgicalInstrument,” published Feb. 23, 2017, the disclosure of which isincorporated by reference herein; U.S. Pat. Pub. No. 2017/0086837,entitled “Compressible Adjunct with Crossing Spacer Fibers,” publishedMar. 30, 2017, the disclosure of which is incorporated by referenceherein; and U.S. Pat. Pub. No. 2017/0086842, entitled “Method forApplying an Implantable Layer to a Fastener Cartridge,” published Mar.30, 2017, the disclosure of which is incorporated by reference herein.Furthermore, in addition to the methods described herein, any of thevarious buttress assemblies described herein may be applied to endeffector (40) in accordance with at least some of the teachings of U.S.Pat. Pub. No. 2017/0056016, entitled “Surgical Stapler ButtressApplicator with End Effector Actuated Release Mechanism,” published Mar.2, 2017, the disclosure of which is incorporated by reference herein;U.S. Pat. Pub. No. 2017/0056017, entitled “Surgical Stapler ButtressApplicator with Multi-Zone Platform for Pressure Focused Release,”published Mar. 2, 2017, the disclosure of which is incorporated byreference herein; U.S. Pat. Pub. No. 2017/0055980, entitled “SurgicalStapler Buttress Applicator with Spent Staple Cartridge Lockout,”published Mar. 2, 2017, the disclosure of which is incorporated byreference herein; U.S. Pat. Pub. No. 2017/0056018, entitled “SurgicalStapler Buttress Applicator with State Indicator,” published Mar. 2,2017, the disclosure of which is incorporated by reference herein; U.S.Pat. Pub. No. 2017/0055982, entitled “Surgical Stapler ButtressApplicator with Multi-Point Actuated Release Mechanism,” published Mar.2, 2017, the disclosure of which is incorporated by reference herein;U.S. Pat. Pub. No. 2017/0055981, entitled “Method of Applying a Buttressto a Surgical Stapler End Effector,” published Mar. 2, 2017, thedisclosure of which is incorporated by reference herein; and/or U.S.Pat. Pub. No. 2017/0086842, entitled “Method for Applying an ImplantableLayer to a Fastener Cartridge,” published Mar. 30, 2017, the disclosureof which is incorporated by reference herein. Various suitable ways inwhich the teachings herein may be combined with various teachings of theabove-cited references will be apparent to those of ordinary skill inthe art.

It should also be understood that the teachings herein may be readilycombined with various teachings in U.S. Pat. App. No. [ATTORNEY DOCKETNO. END8634USNP.0663974], entitled “Adhesive Distribution on Buttressfor Surgical Stapler,” filed on even date herewith, the disclosure ofwhich is incorporated by reference herein. Various suitable ways inwhich the teachings herein may be combined with the teachings of U.S.Pat. App. No. [ATTORNEY DOCKET NO. END8634USNP.0663974] will be apparentto those of ordinary skill in the art.

It should also be understood that the teachings herein may be readilycombined with various teachings in U.S. Pat. App. No. [ATTORNEY DOCKETNO. END8635USNP.0663976], entitled “Configuration of Buttress forSurgical Stapler,” filed on even date herewith, the disclosure of whichis incorporated by reference herein. Various suitable ways in which theteachings herein may be combined with the teachings of U.S. Pat. App.No. [ATTORNEY DOCKET NO. END8635USNP.0663976] will be apparent to thoseof ordinary skill in the art.

It should also be understood that the teachings herein may be readilycombined with various teachings in U.S. Pat. App. No. [ATTORNEY DOCKETNO. END8636USNP.0663978], entitled “Surgical Stapler Buttress withTissue In-Growth Promotion,” filed on even date herewith, the disclosureof which is incorporated by reference herein. Various suitable ways inwhich the teachings herein may be combined with the teachings of U.S.Pat. App. No. [ATTORNEY DOCKET NO. END8636USNP.0663978] will be apparentto those of ordinary skill in the art.

It should also be understood that the teachings herein may be readilycombined with various teachings in U.S. Pat. App. No. [ATTORNEY DOCKETNO. END8637USNP.0663981], entitled “Applicator for Surgical StaplerButtress,” filed on even date herewith, the disclosure of which isincorporated by reference herein. Various suitable ways in which theteachings herein may be combined with the teachings of U.S. Pat. App.No. [ATTORNEY DOCKET NO. END8637USNP.0663981] will be apparent to thoseof ordinary skill in the art.

It should also be understood that the teachings herein may be readilycombined with various teachings in U.S. Pat. App. No. [ATTORNEY DOCKETNO. END8638USNP.0663983], entitled “Packaging for Surgical StaplerButtress,” filed on even date herewith, the disclosure of which isincorporated by reference herein. Various suitable ways in which theteachings herein may be combined with the teachings of U.S. Pat. App.No. [ATTORNEY DOCKET NO. END8638USNP.0663983] will be apparent to thoseof ordinary skill in the art.

It should also be understood that the teachings herein may be readilycombined with various teachings in U.S. Pat. App. No. [ATTORNEY DOCKETNO. END8639USDP.0663985], entitled “Applicator for Surgical StaplerButtress,” filed on even date herewith, the disclosure of which isincorporated by reference herein. Various suitable ways in which theteachings herein may be combined with the teachings of U.S. Pat. App.No. [ATTORNEY DOCKET NO. END8639USDP.0663985] will be apparent to thoseof ordinary skill in the art.

It should also be understood that the teachings herein may be readilycombined with various teachings in U.S. Pat. App. No. [ATTORNEY DOCKETNO. END8640USDP.0663994], entitled “Buttress for Surgical Stapler,”filed on even date herewith, the disclosure of which is incorporated byreference herein. Various suitable ways in which the teachings hereinmay be combined with the teachings of U.S. Pat. App. No. [ATTORNEYDOCKET NO. END8640USDP.0663994] will be apparent to those of ordinaryskill in the art.

It should also be understood that the teachings herein may be readilycombined with various teachings in U.S. Pat. App. No. [ATTORNEY DOCKETNO. END8641USDP.0663996], entitled “Tray for Surgical Stapler ButtressApplicator,” filed on even date herewith, the disclosure of which isincorporated by reference herein. Various suitable ways in which theteachings herein may be combined with the teachings of U.S. Pat. App.No. [ATTORNEY DOCKET NO. END8641USDP.0663996] will be apparent to thoseof ordinary skill in the art.

It should also be understood that the teachings herein may be readilycombined with various teachings in U.S. Pat. App. No. [ATTORNEY DOCKETNO. END9071USNP1.0714576], entitled “Method of Applying Buttresses toSurgically Cut and Stapled Sites,” filed on even date herewith; thedisclosure of which is incorporated by reference herein. Varioussuitable ways in which the teachings herein may be combined with theteachings of U.S. Pat. App. No. [ATTORNEY DOCKET NO.END9071USNP1.0714576], will be apparent to those of ordinary skill inthe art.

It should also be understood that the teachings herein may be readilycombined with various teachings in U.S. Pat. App. No. [ATTORNEY DOCKETNO. END9072USNP1.0714574], entitled “Curved Tip Surgical StaplerButtress Assembly Applicator with Opening Feature for Curved TipAlignment,” filed on even date herewith; the disclosure of which isincorporated by reference herein. Various suitable ways in which theteachings herein may be combined with the teachings of U.S. Pat. App.No. [ATTORNEY DOCKET NO. END9072USNP1.0714574], will be apparent tothose of ordinary skill in the art.

It should also be understood that the teachings herein may be readilycombined with various teachings in U.S. Pat. App. No. [ATTORNEY DOCKETNO. END9073USNP1.0714572], entitled “Curved Tip Surgical StaplerButtress Assembly Applicator with Proximal Alignment Features,” filed oneven date herewith; the disclosure of which is incorporated by referenceherein. Various suitable ways in which the teachings herein may becombined with the teachings of U.S. Pat. App. No. [ATTORNEY DOCKET NO.END9073USNP1.0714572], will be apparent to those of ordinary skill inthe art.

It should also be understood that the teachings herein may be readilycombined with various teachings in U.S. Pat. App. No. [ATTORNEY DOCKETNO. END9075USNP1.0714570], entitled “Curved Tip Surgical StaplerButtress Assembly Applicator with Compression Layer Pocket Feature,”filed on even date herewith; the disclosure of which is incorporated byreference herein. Various suitable ways in which the teachings hereinmay be combined with the teachings of U.S. Pat. App. No. [ATTORNEYDOCKET NO. END9075USNP1.0714570], will be apparent to those of ordinaryskill in the art.

It should also be understood that the teachings herein may be readilycombined with various teachings in U.S. Pat. App. No. [ATTORNEY DOCKETNO. END9080USDP1.0714568], entitled “Applicator for a Surgical StaplerButtress,” filed on even date herewith; the disclosure of which isincorporated by reference herein. Various suitable ways in which theteachings herein may be combined with the teachings of U.S. Pat. App.No. [ATTORNEY DOCKET NO. END9080USDP1.0714568], will be apparent tothose of ordinary skill in the art.

It should also be understood that the teachings herein may be readilycombined with various teachings in U.S. Pat. App. No. [ATTORNEY DOCKETNO. END9081USDP1.0714566], entitled “Buttress Assembly for a SurgicalStapler,” filed on even date herewith; the disclosure of which isincorporated by reference herein. Various suitable ways in which theteachings herein may be combined with the teachings of U.S. Pat. App.No. [ATTORNEY DOCKET NO. END9081USDP1.0714566], will be apparent tothose of ordinary skill in the art.

It should be appreciated that any patent, publication, or otherdisclosure material, in whole or in part, that is said to beincorporated by reference herein is incorporated herein only to theextent that the incorporated material does not conflict with existingdefinitions, statements, or other disclosure material set forth in thisdisclosure. As such, and to the extent necessary, the disclosure asexplicitly set forth herein supersedes any conflicting materialincorporated herein by reference. Any material, or portion thereof, thatis said to be incorporated by reference herein, but which conflicts withexisting definitions, statements, or other disclosure material set forthherein will only be incorporated to the extent that no conflict arisesbetween that incorporated material and the existing disclosure material.

Versions of the devices described above may have application inconventional medical treatments and procedures conducted by a medicalprofessional, as well as application in robotic-assisted medicaltreatments and procedures. By way of example only, various teachingsherein may be readily incorporated into a robotic surgical system suchas the DAVINCI™ system by Intuitive Surgical, Inc., of Sunnyvale, Calif.

Similarly, those of ordinary skill in the art will recognize thatvarious teachings herein may be readily combined with various teachingsof any of the following: U.S. Pat. No. 5,792,135, entitled “ArticulatedSurgical Instrument For Performing Minimally Invasive Surgery WithEnhanced Dexterity and Sensitivity,” issued Aug. 11, 1998, thedisclosure of which is incorporated by reference herein; U.S. Pat. No.5,817,084, entitled “Remote Center Positioning Device with FlexibleDrive,” issued Oct. 6, 1998, the disclosure of which is incorporated byreference herein; U.S. Pat. No. 5,878,193, entitled “Automated EndoscopeSystem for Optimal Positioning,” issued Mar. 2, 1999, the disclosure ofwhich is incorporated by reference herein; U.S. Pat. No. 6,231,565,entitled “Robotic Arm DLUS for Performing Surgical Tasks,” issued May15, 2001, the disclosure of which is incorporated by reference herein;U.S. Pat. No. 6,783,524, entitled “Robotic Surgical Tool with UltrasoundCauterizing and Cutting Instrument,” issued Aug. 31, 2004, thedisclosure of which is incorporated by reference herein; U.S. Pat. No.6,364,888, entitled “Alignment of Master and Slave in a MinimallyInvasive Surgical Apparatus,” issued Apr. 2, 2002, the disclosure ofwhich is incorporated by reference herein; U.S. Pat. No. 7,524,320,entitled “Mechanical Actuator Interface System for Robotic SurgicalTools,” issued Apr. 28, 2009, the disclosure of which is incorporated byreference herein; U.S. Pat. No. 7,691,098, entitled “Platform Link WristMechanism,” issued Apr. 6, 2010, the disclosure of which is incorporatedby reference herein; U.S. Pat. No. 7,806,891, entitled “Repositioningand Reorientation of Master/Slave Relationship in Minimally InvasiveTelesurgery,” issued Oct. 5, 2010, the disclosure of which isincorporated by reference herein; U.S. Pat. No. 8,844,789, entitled“Automated End Effector Component Reloading System for Use with aRobotic System, issued Sep. 30, 2014, the disclosure of which isincorporated by reference herein; U.S. Pat. No. 8,820,605, entitled“Robotically-Controlled Surgical Instrument with Force-FeedbackCapabilities,” issued Sep. 2, 2014, the disclosure of which isincorporated by reference herein; U.S. Pat. No. 8,616,431, entitled“Shiftable Drive Interface for Robotically-Controlled Surgical Tool,”issued Dec. 31, 2013, the disclosure of which is incorporated byreference herein; U.S. Pat. No. 8,573,461, entitled “Surgical StaplingInstruments with Cam-Driven Staple Deployment Arrangements,” issued Nov.5, 2013, the disclosure of which is incorporated by reference herein;U.S. Pat. No. 8,602,288, entitled “Robotically-Controlled MotorizedSurgical End Effector System with Rotary Actuated Closure Systems HavingVariable Actuation Speeds,” issued Dec. 10, 2013, the disclosure ofwhich is incorporated by reference herein; U.S. Pat. No. 9,301,759,entitled “Robotically-Controlled Surgical Instrument with SelectivelyArticulatable End Effector,” issued Apr. 5, 2016, the disclosure ofwhich is incorporated by reference herein; U.S. Pat. No. 8,783,541,entitled “Robotically-Controlled Surgical End Effector System,” issuedJul. 22, 2014, the disclosure of which is incorporated by referenceherein; U.S. Pat. No. 8,479,969, entitled “Drive Interface for OperablyCoupling a Manipulatable Surgical Tool to a Robot,” issued Jul. 9, 2013;U.S. Pat. No. 8,800,838, entitled “Robotically-Controlled Cable-BasedSurgical End Effectors,” issued Aug. 12, 2014, the disclosure of whichis incorporated by reference herein; and/or U.S. Pat. No. 8,573,465,entitled “Robotically-Controlled Surgical End Effector System withRotary Actuated Closure Systems,” issued Nov. 5, 2013, the disclosure ofwhich is incorporated by reference herein.

Versions of the devices described above may be designed to be disposedof after a single use, or they can be designed to be used multipletimes. Versions may, in either or both cases, be reconditioned for reuseafter at least one use. Reconditioning may include any combination ofthe steps of disassembly of the device, followed by cleaning orreplacement of particular pieces, and subsequent reassembly. Inparticular, some versions of the device may be disassembled, and anynumber of the particular pieces or parts of the device may beselectively replaced or removed in any combination. Upon cleaning and/orreplacement of particular parts, some versions of the device may bereassembled for subsequent use either at a reconditioning facility, orby a user immediately prior to a procedure. Those skilled in the artwill appreciate that reconditioning of a device may utilize a variety oftechniques for disassembly, cleaning/replacement, and reassembly. Use ofsuch techniques, and the resulting reconditioned device, are all withinthe scope of the present application.

By way of example only, versions described herein may be sterilizedbefore and/or after a procedure. In one sterilization technique, thedevice is placed in a closed and sealed container, such as a plastic orTYVEK bag. The container and device may then be placed in a field ofradiation that can penetrate the container, such as gamma radiation,x-rays, or high-energy electrons. The radiation may kill bacteria on thedevice and in the container. The sterilized device may then be stored inthe sterile container for later use. A device may also be sterilizedusing any other technique known in the art, including but not limited tobeta or gamma radiation, ethylene oxide, or steam.

Having shown and described various embodiments of the present invention,further adaptations of the methods and systems described herein may beaccomplished by appropriate modifications by one of ordinary skill inthe art without departing from the scope of the present invention.Several of such potential modifications have been mentioned, and otherswill be apparent to those skilled in the art. For instance, theexamples, embodiments, geometrics, materials, dimensions, ratios, steps,and the like discussed above are illustrative and are not required.Accordingly, the scope of the present invention should be considered interms of the following claims and is understood not to be limited to thedetails of structure and operation shown and described in thespecification and drawings.

I/We claim:
 1. A method of applying a buttress assembly to an endeffector of a surgical stapler using a buttress applier cartridgeconfigured to selectively retain the buttress assembly, wherein the endeffector comprises a pair of jaws configured to move between an openunclamped state and a closed clamped state, wherein the end effectorfurther comprises a curved tip, and wherein the buttress assemblycomprises a buttress and an adhesive applied to the buttress, the methodcomprising: (a) positioning the end effector within a channel defined bya housing of the buttress applier cartridge, wherein the jaws of the endeffector are in the open unclamped state, wherein the buttress appliercartridge comprises an opening configured to accommodate the curved tipof the end effector; (b) aligning the end effector within the channel ina longitudinally centered orientation relative to the buttress assemblyselectively retained on a platform of the buttress applier cartridge;(c) clamping the end effector on the platform of the buttress appliercartridge, wherein the platform extends within the channel defined bythe housing of the buttress applier cartridge, wherein the platform iscompressible and comprises a wedge shape, wherein clamping the endeffector on the platform comprises the end effector contacting anactuator sled configured to selectively retain the buttress assembly onthe platform of the buttress applier cartridge, wherein contacting theactuator sled with the end effector moves the actuator sled to releasethe buttress assembly from the platform, and wherein at least a portionof the curved tip of the end effector is received by the opening of thebuttress applier cartridge during clamping; and (d) adhering thebuttress assembly to the end effector, wherein adhering the buttressassembly comprises one of the pair of jaws of the end effectorcontacting the adhesive on the buttress.
 2. The method of claim 1,wherein the opening comprises an edge having a tapered surfaceconfigured to guide the end effector during clamping.
 3. The method ofclaim 2, further comprising guiding the curved tip of the end effectorinto the opening to promote alignment of the end effector longitudinallyrelative to the buttress assembly selectively retained on the platform.4. The method of claim 3, wherein guiding the curved tip of the endeffector comprises the curved tip of the end effector contacting thetapered surface of the edge of the opening during clamping.
 5. Themethod of claim 1, wherein the opening comprises a slit.
 6. The methodof claim 1, wherein the opening is expandable as the curved tip extendsthrough the opening during clamping.
 7. The method of claim 1, whereinthe buttress applier cartridge comprises a proximal alignment featureconfigured to contact a tissue stop of the end effector prior toclamping.
 8. The method of claim 7, wherein aligning the end effectorwithin the channel comprises the tissue stop of the end effectorcontacting the proximal alignment feature.
 9. The method of claim 7,wherein the proximal alignment feature comprises a rigid structure thatextends proximally from the platform and is thinner than the platform.10. The method of claim 1, wherein the opening comprises a U-shapedslit.
 11. The method of claim 1, further comprising opening the endeffector after clamping on the platform and removing the end effectorfrom the channel defined by the buttress applier cartridge.
 12. Themethod of claim 1, wherein the opening is defined by a hole in a distalportion of the platform, wherein the opening is located distal to wherethe buttress is selectively retained on the platform.
 13. The method ofclaim 1, wherein the buttress applier cartridge comprises a distalalignment feature configured to contact the curved tip of the endeffector during clamping.
 14. The method of claim 13, wherein the distalalignment feature comprises a pair of resiliently biased self-centeringlateral arms arranged about the opening.
 15. The method of claim 1,wherein the curved tip of the end effector is a dissecting tip.
 16. Amethod of applying a first buttress assembly and a second buttressassembly to a first jaw and a second jaw of an end effector of asurgical stapler, wherein each of the first and the second buttressassemblies comprises a buttress and an adhesive applied to the buttress.the method comprising: (a) positioning an open end of a buttress appliercartridge adjacent to the end effector of the surgical stapler, whereinthe buttress applier cartridge is configured to selectively retain thefirst and second buttress assemblies on opposing surfaces of a platformof the buttress applier cartridge; (b) positioning the end effector, inan open unclamped state, within a channel defined by a housing of thebuttress applier cartridge such that the first jaw of the end effectoris located adjacent to the first buttress assembly, and the second jawof the end effector is located adjacent to the second buttress assembly;(c) guiding the end effector relative to the buttress applier cartridgeto align a curved tip of the end effector with a pocket formed in theplatform of the buttress applier cartridge, wherein the pocket isconfigured to accommodate the curved tip of the end effector when theend effector is in a clamped closed state; (d) clamping the end effectoron the platform of the buttress applier cartridge, wherein clamping theend effector on the platform comprises the first jaw of the end effectorcontacting a first pair of actuator sleds to selectively release thefirst buttress assembly from the platform of the buttress appliercartridge, wherein clamping the end effector on the platform furthercomprises the second jaw of the end effector contacting a second pair ofactuator sleds to selectively release the second buttress assembly fromthe platform of the buttress applier cartridge, and wherein at least aportion of the curved tip of the end effector is received by the pocketof the buttress applier cartridge during clamping; (e) adhering thefirst buttress assembly to the first jaw of the end effector, whereinadhering the first buttress assembly comprises the first jaw of the endeffector contacting the adhesive on the buttress of the second buttressassembly; adhering the second buttress assembly to the second jaw of theend effector, wherein adhering the second buttress assembly comprisesthe second jaw of the end effector contacting the adhesive on thebuttress of the second buttress assembly; and (g) opening the endeffector after clamping on the platform and removing the end effectorfrom the channel defined by the buttress applier cartridge.
 17. Themethod of claim 16, wherein the pocket comprises a slit in the platform.18. The method of claim 17, wherein the slit is perforated.
 19. Themethod of claim 16, wherein the buttress applier cartridge comprises aproximal alignment feature configured to contact a proximal edge of theend effector when in the open unclamped state to align the end effectorlongitudinally relative to the channel defined by the housing of thebuttress applier cartridge.
 20. A method of applying a buttress assemblyto an end effector of a surgical stapler using a buttress appliercartridge configured to selectively retain the buttress assembly,wherein the end effector comprises a pair of jaws configured to movebetween an open unclamped state and a closed clamped state, and whereinthe buttress assembly comprises a buttress and an adhesive applied tothe buttress, the method comprising: (a) positioning the end effectorwithin a channel defined by a housing of the buttress applier cartridge,wherein the jaws of the end effector are in the open unclamped state;(b) aligning the end effector within the channel in a longitudinallycentered orientation relative to the buttress assembly selectivelyretained on a platform of the buttress applier cartridge, wherein thebuttress applier cartridge comprises a proximal alignment featureconfigured to contact a tissue stop of the end effector prior toclamping, and wherein aligning the end effector within the channelcomprises the tissue stop of the end effector contacting the proximalalignment feature; (c) clamping the end effector on the platform of thebuttress applier cartridge, wherein the platform extends within thechannel defined by the housing of the buttress applier cartridge,wherein clamping the end effector on the platform comprises the endeffector contacting an actuator sled configured to selectively retainthe buttress assembly on the platform of the buttress applier cartridge,wherein contacting the actuator sled with the end effector moves theactuator sled to release the buttress assembly from the platform; and(d) adhering the buttress assembly to the end effector, wherein adheringthe buttress assembly comprises one of the pair of jaws of the endeffector contacting the adhesive on the buttress.